I have an electrial-related problem with my Honda CBR F4 that I can`t seem to isolate. Hopefully someone here can point me in the right direction.
This all started when the bike intermittently wouldn`t charge the battery while running. Every once in a while I would go to start my bike and it would be dead. I either jumped started it or trickle charged the battery and I was good to go. It would happen maybe once every 6 months - then more often.
I started the bike and checked the voltage 5/6K RPM; I cant remember exactly what the numbers were but it never got higher then about 12.3..very, very minor fluctuation in the voltage no matter where my rpm was.
I had the battery checked and it had a dead cell, I was also recommended to change out the reg/rec. I installed a new battery and a new reg/rec; bike died while I was riding, and when I went to try and start it bike was completely dead. So the bike wasn't charging at all, and was running only off the battery.
I replaced the stator. Started the bike with a freshly charged battery and saw no voltage change at all. Battery held a steady 12 volts. No change at all with with RPM.
I unplugged the stator to check the voltage across all 3 wires to diagnose that the new stator was making current. The bike wouldn't start. When I turned the key I got headlights, press the starter and the headlights dim but no click, and no starter motor. Nothing. Just dimming headlights. Safety switch was in RUN position and in neutral. I tried pulling in the clutch and side stand. Nothing, no clicks, just dimming headlight. (The bike should start without the stator plugged in, correct?) I plugged the stator back in and got the same problem. Sweet. Now I can't get the bike started to check why my bike won't charge.
I checked the starter. I tried jumping the two main power leads screwed to the starter relay, I got the starter kicking but the engine wouldn't catch.
Next I checked the starter relay. I pulled back the rubber on the relay connector (there are 4 wires). I tested the two red wires to battery ground and found 12 volts. I checked continuity from the green ground wire to ground and got infinite resistance (not sure if that's an issue or not?). I then jumped the connectors red wire to the yellow wire. Got the relay click and the started engaged and started kicking. Again I tried starting the engine but the engine wouldn't catch.
At this point I'm assuming whatever is not letting me start the engine from the starter button is also keeping the engine from starting when jumping the relay, bypassing the safety switches. Fuel pump maybe??
I pulled the leads off the clutch safety switch, I checked the actual switch by checking resistance across the two bare leads. With the clutch resting I got infinite resistance; pulled in the clutch and got no resistance.
Next I check resistance from the two clutch switch wires. One of the wires I got a dead short to the green ground wire on the starter relay connector (the one I couldn't got a short to ground earlier). On the other, which I assume should short to ground - I got infinite resistance. I couldn't pickup ground to it, is this a problem?
Not sure if I'm on the right track here or what, but definitely looking for a few extra eyes on this problem - driving me nuts. And I still haven't got back to why the stator inst charging the system - I probably replaced a perfectly working stator since I'm had the same problem in the brief time the bike was running.
ANY thoughts appreciated. Cheers!