Good Day, I picked up a 2003 DL1000 this summer. It was a good price but had not been taken care of for a long time. Am pretty sure it has spent some of its life outdoors. It needed Tyres, brakes, chain/sprocket, wheel bearings steering bearings, fluids changed, etc. I can do the work myself so was a good enough price to buy.
But I don't know electrical, am learning as I go.
The bike died while riding it, battery was drained. I changed the battery since it was old and the bike was ridden for another week or two.
The bike died again while riding. The stator check looked bad, I changed it and indeed one of the poles was burnt out. I changed the rectifier as well. The new stator has 20v at idle across the three phases, the new rectifier has a good diode test with consistent values for all the diodes.
The bike still does not charge. The voltage of the battery @4000rpm is something like 0.1v higher than the voltage at idle, which is the same as the voltage of the battery with the engine off.
I have checked continuity for all fuses in the fuse box, and the starter relay "main fuse". Each fuse was removed and put back in, although I have not changed any the fuses.
The wire diagram (and this is my first time reading one,) shows that the rectifier power goes to the starter relay, and from there to the battery. The ground goes into the wire harness and then everywhere.
With battery disconnected, continuity for the two red wires (wire harness connector, rectifier disconnected) from the rectifier to the starter relay connector look good. Continuity for the two black wires from the rectifier to the starter relay connector show high ohms, one at 30K, one at 7M. However these values change with the ignition switch in the on position, although still show resistance. I didn't write down the values.
I haven't taken off the tank and fairings yet, so I haven't checked the frame and engine grounds for corrosion yet. I do not know where they are.
After chatting with a friend, he suggested using a battery that is known to be good and see what happens. Next, to take out the starter relay and check it properly. Next, to take the fuse box out and check it properly. Next, to start opening up the wiring harness in the area of the rectifier/starter relay (they are close beside eachother) and check the wiring.
Some questions, for which I am hoping people can point me in the right direction,
Does anyone know if the ground resistance I mentioned above is an indicator of a problem, or is that to be expected? I ask the question because the ohms changing with ignition on vs off tells me more is happening behind the scenes.
Are the next steps I am planning to do correct, or should I be checking something else?
If it turns out to be corrosion in the wire harness, and I decide that I want to replace it instead of taking it apart, can anyone confirm what year DL1000 wiring harness' are compatible? Ebay says 2002-2006, however oem part numbers are different for every year. I would want to buy with confidence, if I don't know for certain then I would just be looking for a 2003 wire harness...
Any help would be appreciated, I'm at the end of my knowledge before I start doing a teardown on the bike,
