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Hi all. I have an 2006 900b with 30k and I love it! I have a question about the charging system. I replaced the stator, rectifier and battery about 1000 miles ago. I installed the Ricks stuff off a tip I got on here last fall. last night when I pulled off the interstate to get fuel the battery was dead. After walking home to get the truck and going back to bike to pull the batt then back to the house I put it on a 2 amp charge and the Battery takes a charge. I took the battery back to the place I purchased it they did a load test and said it was good, 249 cold cranking amps but it only had 11 V so I put it on the trickle and got it up to 13 v. Bike starts. Since the batt took a charge from the trickle but only had 11 v when I took it out of the bike. Looks like rectifier or stater right? I
I unplugged the rectifier plug and it had oil in it!?! like an oil magnet!! Forks are clean brake cal is clean no leaks or drips from filter or motor or anywhere else. Completely dry yet the plug was wet!! WTH? Hopefully this is the problem After charging the battery on a trickle to 13.2 I put it back in the bike. Started and i let it get to operating temp and volt meter said 13.8. I rev it and voltage went to nearly 15, I backed off and it dropped back to 13.8 and held. So strange why yesterday bike would not start and battery only had 11 volts when I checked it after I took it out. I could not test output cuz it wouldn’t start. I have added 0 electric accessories. Hopefully just a dirty connection at the rec/reg plug? I think im a little more confused today than I was yesterday. Has this happened to anyone else? Ideas? suggestions? I’m afraid to venture out of my neighbor for fear of needing to call the wife to come rescue me!!
 

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I had to change out the stator on my 07 900 Custom at about 21k miles. When I first started looking to find the charging problem I also found what appeared to be oil in that plug. I don't really know what it was or where it came from but after replacing the reg/rec I have always used dielectric grease to lube the contacts and seal the plug. 30k miles later I haven't had a charging problem or 'oil' in the plug.

You should do some charging system checks though. Check the AC output of the generator and the DC voltage across the battery terminals while running (at a minimum). This will give you an idea as to whether or not your system is trying to charge the battery or whether you need to do more testing. To check the AC output properly, you'll need a tach along with your voltmeter.

Also, once you get the problem worked out, consider installing a battery gauge. I put a Kuryakyn on mine. Depending on how you wire it up it can monitor your system voltage or charging voltage. It won't tell you everything about your electrical system. I refer to it as my peace of mind gauge.
 

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Thanks Steve. I put the voltmeter on the battery while running and got 13.2v -15 v. After cleaning this plug. Unsure of the rpm’s though. Just played it by ear so not exact but...... I will dielectric it and heat shrink that plug and wiring to it. Hopefully that gets it. Thanks much.
 

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Next most important question I think, is how did the oil get inside the rectifier plug? Is this from doing oil changes?
 

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I don’t think so. Tonight I unplugged it and it was wet again. I pulled the plug back toward the rear so I could spray contact cleaner up in there and let it dangle. I was shocked at the oil that dripped out, I left it for 30 minutes and 1/2 cup of oil was on the floor. It must be coming from the case. I’m going to do an oil change tomorrow and pull off the stator cover and see what’s going on in there.
 

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To be clear. The oil wasn’t actually coming out of the plug but out of the tubing/casing that wraps up those 6 wires going into the plug.
 

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To be clear. The oil wasn’t actually coming out of the plug but out of the tubing/casing that wraps up those 6 wires going into the plug.
That is weird. Mine had a little liquid in the plug. This sounds like crankcase oil following the wires.
 

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That is weird. Mine had a little liquid in the plug. This sounds like crankcase oil following the wires.
I believe that's exactly what it is. When I had my 900 and replaced my stator I found oil in the connector both before and after the repair. Breaking it down I found that it appears the oil from the case is following the inside of the insulating wrapping around the wiring to the rectifier. Obviously a design flaw, if this is whats happening. I wound up cleaning the oil from the inside of the wrapping, put some rtv silicone sealant inside it and wrapped a zip tie around the outside. That appeared to stop the oil which bolsters the belief it's coming from the case.
 

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Hi CarGuy. Thanks for confirming. Your fix is exactly what I’m going to do. Between the oil in this shield and the oil in the air box I’m a 1/2 q low!!
 

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Hi CarGuy. Thanks for confirming. Your fix is exactly what I’m going to do. Between the oil in this shield and the oil in the air box I’m a 1/2 q low!!
Oil in the air box - if a lot and the crankcase oil level is 1/2 quart low according to the sight glass, is the crankcase oil being over-filled? With my 900 if the oil level is any higher than midway between the oil level marks there will be more than a little oil in the air box. Possibly over-filling the oil is causing some to leak from the air box and run down onto the electrical connector. Mine has had some oil on it - some from oil changes - oil leaks from filter when uninstalling, and also likely from overfill.
 

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@Scottso: regarding your battery, if everything checks out (your voltage read seems perfect) also make sure the battery terminals are properly torqued. I have experienced twice lose bolts on the battery. the fact that the lead is compressible apparently causes the bolts to loosen under the engine's vibrations... one time the bike was not charging the battery properly and I discovered that the post on the right was not tight.. i used a split washer. the second time the battery wasn't turning over the engine energetic enough for a new battery and this time both bolts were not tight enough. now i'm using temporary thread lock (blue) and a socket (not the screw driver) to secure the battery terminals.


-I also noticed oily liquid in the rectifier's plug, not just once.. i ended up plugging the protector tube that houses those wires with some shop towel..
one time i traced the wires all the way to the engine case and believe it or not they were dry coming out of the engine.. but that is the only way oil can get to that plug.. anyways, it was never a dripping issue.
-another place that can get oily is the oil filter cover... that is from the breather.. perfectly normal especially under high RPM and oil being filled to the top.
-the 'scariest' spot to see a leakage is underneath the bike right side.. there's a little pressure valve corresponding to the water pump (an actual vertical hole). if i'm not mistaken that can spit out some oil too, but it does spit out some coolant under high RPM. it can reach the oil drain plug as the bike is parked... perfectly normal too.
 
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