I'm now on my 4th Electrex World Reg/Rec !

[pasotibbs]

I'm now on my 4th Electrex World Reg/Rec !!!

The first failed after a few months (Gen light on, not charging) and was replaced under warranty,the second was outside warranty but luckily the third was within.The reason for this post is that the second and third have both failed in exactly the same way and when I contacted EW and described the fault they informed me that my replacement would be "an improved design", the replacment does appear externally slightly different but time will tell !!!

The last two units have both shorted out (the body of the unit has become battery +ve) but luckily I ignored the installation instructions and fused the Battery +ve so possibly prevented a loom fire !!!

The last one actually totally discharged my battery (it hasn't recovered, so has had to be replaced)but didn't blow the fuse the first blew the fuse.

I removed the potting compound from the Reg/Rec this afternoon and as I suspected the problem is exactly the same as last time with a short between the +ve part of the board and the body(it's only approx .5mm clearance) with evidence of scorching visible in 2 or 3 areas and when these areas where cleaned the short was cured.

 

I suspect water may get in between the potting and the unit body and the corrosion eventually leads to a short but I'm open to other ideas, the redesign implies that it may possibly be a known issue ?

 

just a heads up for anyone who has one of thes units

 

Dave

[gstallons]

How much are you saving buying this unit instead of OEM ?

[fotoguzzi]

how do you get that potting material out? then you can fix it right? I have a stock reg that I'd like to try that with.

[pasotibbs]

how do you get that potting material out? then you can fix it right? I have a stock reg that I'd like to try that with.

A heat gun softens the compound and it is then possible to remove it bit by bit while it is still hot,but once it cools it becomes solid again.

[emry]

I think I would try another brand at this point.

[pasotibbs]

I think I would try another brand at this point.

So far I have been unable to find an alternative that will keep the Gen warning light.I put the last failure down to bad luck as I'm sure others here have used this product with no issues but after the second failed in exactly the same way.....

It may be that the "improved design" resolves the issue, we will see !!

[raz]

I replaced with an OEM last year but it was a tough decision. Can't remember price difference now but that was not the main issue anyway, the OEM has a pretty bad rep too. Hopefully you just had bad luck, good thing you got the redesigned one on warranty!

[pasotibbs]

Another failure !!

I've hardly used the bike in the last few years and not at all for the last 2 and the reg/rec has again shorted out internally with a 5 amp (on an ammeter ) link between +ve and the body of the unit which totally discharged the battery (it has taken a charge by linking another battery in parallel and is holding above 12v but suspect will prove to be weakened ).

I normally have the battery on charge 2 hours every day (on a timer) and run the bike every couple of months but accidentally switched off the socket for a few days and when I noticed and switched it back on discovered the battery totally flat.

 

It must be me but my 26yr old Ducati is treated exactly the same and is still on its original Reg/Rec !

[gstallons]

Disconnect one terminal of the battery , fully recharge the battery , wait one day and then check the battery voltage . If is is down , the battery will not hold a charge and needs replacement .  If it is good , you have a drain and is running the battery down and you need to find the source of the drain .

[Stick]

When I noticed my "new" 2002 Lemans was charging too low (12.5V), I went thru the charging circuit starting at the stator.  Dummy loaded the stator to ensure that the 60VAC I was seeing was "real".  Then I decided to swap in a spare Ducati 3 phase RR that I use to carry on my Duc ST2 "just in case".  You use only 2 of the 3 yellow wires on the newer RR, and tape the 3rd one.  This RR works great - it charges at just over 14V, and the AGM battery is very happy with this.  

 

You can find these for less than $50 used. (eBay, Gotham Cycles, etc).

 

The only downside is that  you don't have the GEN light any more.  I use the voltmeter function built into my Escort 8500 x50.  "Never leave home without it."  ;-)

[GuzziMoto]

I have seen where if I have a battery charger hooked up to a battery but the battery charger is not plugged in it can drain the battery.

If that is what you said (I think it was) it sounds normal. Hopefully the battery will still hold a charge once charged up.

[Kiwi_Roy]

The Electrosport ESR510 is a direct connected (doesn't use the flakey Voltage reference from the headlight relay) and it still has the charge light.

 

I've also been looking at the Shindengen (Japanese) regulators, they make the components.

I believe these are used as OEM on several brands. A 3 phase one will also work with our single phase Guzzis
The Mosfet FH020AA seem to be the way to go

This is a direct connected shunt type so you no longer have to worry about the flakey headlight relay reference.

[pasotibbs]

[Kiwi_Roy]

Next comes the tricky part, getting the board out in one piece