Low voltage/ not charging

[AMechEng]

Ya ordered the R/R from Tampa and it shipped today Priority. Scheduled delivery is Friday. Hopefully I'll be riding Saturday!

 

[Miles Long]

Yes!

Kopr-Shield is a great product. Its copper suspended in anti-corrosion paste to oversimplify it.

Generally used in industrial electrical arena between bolted mating surfaces on "big stuff" cabling or threaded pipe joints for improved ground continuity.

Also good to paste on wire before crimping down end connectors.

If you consider using it to coat small "unpluggable" connectors like we have keep in mind it IS conductive so be sure to keep it confined to the individual points so it doesn't short out across different wires on the same connector.
I haven't used it in any of my plug connectors but if I did I would apply it to the interior of the individual female connectors with a toothpick or q-tip

I here ya. I've used many of those 2, 3, and 4 gang rubberized "trailer connectors" and only use non-conductive Di-electric grease when sticking them together. These connectors are dandy for items removed often, such as stereo components, saddlebag and fairing lights, and aux. driving lights. Tight fitting ones, together with the grease, makes for very little voltage loss across the connector. Easy to check with a meter. However, I wouldn't think of using them on a critical connection like the stator to RR. For this, currently (no pun intended), I'm using three individual bullet connectors, with Kopr-Shield, individually taped. I didn't want a permenant soldered connection, in case I want to test stator output.
Cheers!

 

[AMechEng]

Who says soldered connections are permanent. It take 10 seconds to solder a connection and another 10 seconds to put some shrink wrap around it.

 

[AMechEng]

I've been working on the electrical checking the resistances between points. I found there was some resistance between the engine and frame (1 ohm) so I ran a grounding wire (heavy gauge) and now there is none. I also found that there is a small grounding wire that goes from the harness to the battery negative terminal. When I tested resistance at that grounding wire to the frame I found 8 ohms resistance. Where is a good spot to ensure that the harness is properly grounded to the frame?

 

[AMechEng]

Yesterday I added heavy wiring between all the critical points I could find and soldered all the connections. I used the factory connectors (Furukawa QLW .250” Connectors) to the R/R. I replaced the R/R (even though I think my other one is good) with another one from a ZX14 (FH010). I charged the Shorai battery last night and when I checked the voltage this morning (after it had a few hours for surface charge to dissipate) it was at 13.3 voltage with key off. I started the bike and let it idle for a bit and within a minute the voltage came up to 14.4-14.5 and held at 800 RPMs. I've never seen this kind of voltage on this bike so it's a good feeling. I'm skeptical it will stay there since there has been so many issues with the charging system.

 

[alorio1]

Reading thru the thread it looks like you have covered everything that needed to be addressed, and did a good job. I believe you have a sound healthy charging system.......