748/916 etc.: Check your generator wiring!

Discussion in '748 / 916 / 996 / 998' started by JimDane, Jul 16, 2012.

  1. I just missed half a trackday - my track-916 suddenly started sputtering like crazy, the rev. counter went dead and I lost battery power.

    The yellow wiring from the regulator runs through TWO connectors (and the wiring gauge is too thin), which caused the battery charging wires to melt down and short out.

    I changed the wiring to larger gauge and removed all the connectors, now it runs strong again. Luckily neither the generator nor the Rectifier/Regulator went dead in the process. I am considering to put a small digital voltmeter in to keep an eye on it.

    So: Check the yellow wires under your bike behind the plate holding the regulator. You have either 2 or 3 yellow wires (2/3 fase generator) ending in a plug from the regulator. The second plug is behind the battery case.

    Jim
     
    #1 JimDane, Jul 16, 2012
    • Like Like x 1
  2. yes, it's a known problem Jim that was documented to saturation point on Ducatisti by many people and well worth reminding everyone as at worst can result in bike catching fire if ignored.
     
    #2 Chris, Jul 16, 2012
    • Like Like x 1
  3. on the subject of 748/916 spontaneous combustion..its also worth mentioning the foam bell filters in the airbox..i returned to stock after i had an 'incident'. these can catch fire quite nicely too..something to do with high octane fuel, flammable foam, oil, heat, and oxygen, but im not 100% sure. luckily i got away with a new airbox and warm buttocks.
     
    #3 funkyrimpler, Jul 17, 2012
  4. The alternator wiring is a potential problem, particularly on the older, single-phase bikes (916 and pre'99 748).

    As for the in-airbox filter catching fire; if your bike's running lean it may backfire through the intakes and an oil-soaked filter is not the best extinguishing material, especially one that's being fed with a nice air supply and sits directly under 17L of petrol... :eek:
     
    #4 Dukedesmo, Jul 17, 2012
  5. #5 Birdie, Jul 17, 2012
  6. totally agree funky - first 996 had evidence of (JPL?) filter catching fire - melted drips were still stuck fast to one of the butterflys.. If it ever happens and starts to smoke after backfire and stall, the best thing to do is start engine again as quick as possible*.


    *not sure if shower injector types ever had a similar one-piece aftermarket filter above inlets (can't see that they would) but if this is the case then please disregard this comment. (TFIC)
     
    #6 Chris, Jul 17, 2012
    Last edited: Jul 17, 2012
  7. Remember if you upgrade the wiring, take it all the way to the solder join on the stator.

    There are other upgrades, I run a Yamaha R1 rectifier under the seat on my '97 748, AWG10 wiring all the way through and a heavier grade earth lead from the battery.:upyeah:
     
    #7 srad34, Jul 17, 2012
  8. What a brilliant little gadget! I was looking for a voltmeter but this is so much better, smaller, lighter.

    Jim
     
    #8 JimDane, Jul 18, 2012
  9. #9 Nelson, Jul 18, 2012
  10. Mine is fitted in the clock surround, bottom right of the rev counter.
    Steve


    And here is a pic.

    dash.jpg

    dash.jpg
     
    #10 Birdie, Jul 18, 2012
    Last edited: Jul 18, 2012
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