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Electrical & Rev Counter Guide - How to

romi

biker, times two
#1
Just attaching a guide from Fuel_2001. I am sure he will introduce this one to you all.


Keywords: battery, regulator, rectifier, rev counter, charging, alternator, CDI, ECU
 

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fuel__2001

engineless with 2 wheels
#2
firstly thanks to

Romi, Mudplug, Midori and Agent for various things in putting this guide together, they have all contributed in some way.

In this guide you will find information that kawasaki wont give you or haynes doesnt have. I/we hope you find it useful, if you have any comments or other ideas please feel free to post away.

Cheers

Fuel
 
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romi

biker, times two
#3
Other things to consider: A Battery Status Monitor, spray the electrical connectors with silicone grease/GT85 or similar in the summer (to avoid trapping damp), carry a spare RR underneath the seat.

Attached is the diagram of the Haynes manual 32.3b - IT IS WRONG. Also ignore 32.3a which does not correspond to the ER-5 neither.
 

Attachments

romi

biker, times two
#5
Fuel number one - the rest Team effort

firstly thanks to Romi, mudplug and agent for various things in putting this guide together, they have all contributed in some way.
@ Fuel: :congrats: - the guide wouldn't be here without you ;)

I hate mentioning names when I write a guide as I always forget someone :headsmash

:gossip: Thanks to Midori, for sharing with us the undercharging problems she faced and better still bother to take some pics of the pinched wiring :five:

Let's see the ER-6 members writing guides - A COMPETITION :beer:
 
#6
Thank you for all the ideas when my bike was... broken. I did nothing actually, I just broke it. No need for thanks. I'm glad if it helps someone.
 
#8
In this guide you will find information that kawasaki wont give you or haynes doesnt have. I/we hope you find it useful, if you have any comments or other ideas please feel free to post away.

Cheers

Fuel

Thanks Fuel, your a star.

My rev counter dont work so i had a look and i need the 30ohm capasiter diode thing??? cause mines fryed! cause unknown???

Could the guy i got it bashing the clocks in a low speed off cause that???
 

romi

biker, times two
#9
My rev counter dont work so i had a look and i need the 30ohm capasiter diode thing??? cause mines fryed! cause unknown???

Could the guy i got it bashing the clocks in a low speed off cause that???
The only cause known to me is a RR failure, which lets all the electrics run well over 15V.
 

fuel__2001

engineless with 2 wheels
#10
Thanks Fuel, your a star.

My rev counter dont work so i had a look and i need the 30ohm capasiter diode thing??? cause mines fryed! cause unknown???

Could the guy i got it bashing the clocks in a low speed off cause that???
It wont be just the resistor thats fried, the diode will be blown too. What caused the damage will be an overcharge of the system.

As Romi said, a faulty regulator rectifier is the only known cause to damage the rev counter. Has the RR been changed recently, or have you checked the charge with the bike running?
 
#11
It wont be just the resistor thats fried, the diode will be blown too. What caused the damage will be an overcharge of the system.

As Romi said, a faulty regulator rectifier is the only known cause to damage the rev counter. Has the RR been changed recently, or have you checked the charge with the bike running?
I jus got the bike so havent had much of a play yet, going on how grubby it was i doubt anything had been changed checked or looked into! took me 1 1/2hrs and half a litre of white spirt to clean the crap of the back wheel alone! How can you expect your ride to be a good one if you dont give it some love?

How can anyone treat their bike as a work horse and not the smile inducing tool it is? A little bit of tlc and life would be so much better!
 

fuel__2001

engineless with 2 wheels
#12
discussion

from a discussion on this thread

This might be something to add in the guide as a caveat - even though everything else may work and you repair the components on the RC. The chip on the RC might still be U/S thus rendering the RC useless. Other issues created by a duff chip might also be lag of the needle, which has been seen by others on here who have repaired the RC.
 

fuel__2001

engineless with 2 wheels
#13
findings

Romi

This guide needs updating as i have something further to add.

Preliminary reports indicate that I've hopefully worked out a way to repair the RC and stop the needle lagging when you put it all back together :D

Good as new :smokin:
 

romi

biker, times two
#14
just send it to me (you have my email address) and I will do the changes. Then I can added to one of your previous posts ;)
 

mudplug

Unclassified Rider.
#16
Um... well the bike's still in bits at the moment so I can't test it yet :( and I don't know for certain if I've actually got a CDI with working RC circuitry, though I know that the bike did start with one of the CDIs.
 
#17
Um... well the bike's still in bits at the moment so I can't test it yet :( and I don't know for certain if I've actually got a CDI with working RC circuitry, though I know that the bike did start with one of the CDIs.
Does it require much work to test.? You could send it to me and I'll do it.?
 

mudplug

Unclassified Rider.
#18
Basically just need to connect it to the clock loom, connect clock loom to bike and start / rev bike.

I suppose you could disconnect the revcounter part of the clock loom without completely stripping / removing clocks, e.g. if you removed one revcounter screw at a time to release the ring terminal, then put the screw back in again... did this with each of the 3 screws, then used different screws to connect up the repaired RC to the loom.
 
#19
Basically just need to connect it to the clock loom, connect clock loom to bike and start / rev bike.

I suppose you could disconnect the revcounter part of the clock loom without completely stripping / removing clocks, e.g. if you removed one revcounter screw at a time to release the ring terminal, then put the screw back in again... did this with each of the 3 screws, then used different screws to connect up the repaired RC to the loom.
Sounds like I should leave well alone. :)
 

fuel__2001

engineless with 2 wheels
#20
I don't know for certain if I've actually got a CDI with working RC circuitry, though I know that the bike did start with one of the CDIs.
You can test the RC part of the CDi; you dont need to mount the CDi to the bike with the RC attached - check the guide ;)
 
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