electrical help !!

A batt may read 12v but not have enough power to crank it over. Pull that batt and get it tested. Even if it is good, while putting it back in, you'll be able to ensure good solid connections.

Next, check the VR output. Should be about 14.4V.

Welcome to the site

nsmisfit1 said:

Voltage reg

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nsmisfit1 said:

Stator issue?

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The 400's were unfortunately plagued by faulty VR's from the factory, there was a whole recall and update and all, way back in the day. If your factory VR has survived all these years, while shocking, it's also probably the culprit. You're on the right page, it sounds like it's either the VR or stator.

Download your free service manual here on the site and check 'em both for proper operation

Duece said:

A batt may read 12v but not have enough power to crank it over. Pull that batt and get it tested. Even if it is good, while putting it back in, you'll be able to ensure good solid connections.

Next, check the VR output. Should be about 14.4V.

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Thanks Deuce. I do have another battery coming. The other one is no good. My next plan of action was to check the VR. Thank you for confirming my thoughts. Much appreciated!!

BombardierBomb said:

Welcome to the site




The 400's were unfortunately plagued by faulty VR's from the factory, there was a whole recall and update and all, way back in the day. If your factory VR has survived all these years, while shocking, it's also probably the culprit. You're on the right page, it sounds like it's either the VR or stator.

Download your free service manual here on the site and check 'em both for proper operation

Click to expand...

Thanks for the welcome !!
I can't say for sure if this was the origional VR as I bought this second hand. But that info is good to know. Once I get the new battery in and get it running, I'll check the VR. I know you can can take it off and do a bench test, but that's over my head..haha. I was hoping it wouldn't be the stator. Is there an easy way to check?
Again, thank you for the valuable information. I do appreciate it!

Just to confirm.... A faulty stator or an over charging VR could cause all the lights to light up on my dash? I understand the engine quitting if it's not getting enough feed from the regulator ( if the battery went dead). I've never seen this happen before, and I suppose I'm just trying to ease my mind...haha
Thanks !

The old VR's were just a single-plug, the new ones are dual-plug. Pretty easy visual cue as to whether or not yours is still original.

But yes absolutely, the battery firing the plug and running what minimal electrical that thing does have, will eventually discharge to a point where it can't anymore, if the VR and/or stator isn't replacing that juice, and the bike dies.


Free service manual ^ for ya

Again...good to know.. thank you! Sounds about right. Mine has the 2 plugs, but can still fault out I'm sure.
And thanks for the manual link!! That's going to come in handy.
Almost want to bite the bullet and just replace the VR and stator anyway. See how it goes. Maybe I'll test them first.
Thank you

nsmisfit1 said:

Almost want to bite the bullet and just replace the VR and stator anyway. See how it goes. Maybe I'll test them first.
Thank you

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The battery is the easiest to remove and test and the best place to start. A under charged battery can skew any charging system test results.
Removed it, fully charge it on a slow 2 amp or less charge (a Battery Tender if you have one) and have it load tested.

If the battery tests good, reinstall and do a engine running voltage test for charging voltage in the range of 13.5 - 14+ volts with headlights off and at a raised RPM

Thanks for the advice. I have tested the battery and am replacing it. Next step was to check charging voltage then stator. Hoping for just a vr issue.
Appreciate the help.. thank you.

Be sure to also clean and tighten any ground cables and wires. I like to coat them with copper anti seize to promote a good connection and prevent corrosion.

Rocketdog said:

Be sure to also clean and tighten any ground cables and wires. I like to coat them with copper anti seize to promote a good connection and prevent corrosion.

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Thanks for the advice!! Will definitely go over the connections, and add the anti seize of that's going to help.

*UPDATE *
Just wanted to give an update. But first, thanks again for the information y'all provided.
Well, I bought a new battery and installed it. Then I static tested the stator, which tested good. I started 'er up and did a dynamic stator test, which also tested good. Which leaves, so I thought, the VR, and I ordered one. It arrived and I immediately put it on. Started the rig up and .....still not charging. Looks like I should have checked wiring before ordering the VR, huh. Am I wrong in thinking that the issue is now in the wiring since there are only 3 components to the charging system? (battery, stator and VR).

>Much appreciated<<

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PS..."400outymisfit" is me on another device.

nsmisfit1 said:

Am I wrong in thinking that the issue is now in the wiring since there are only 3 components to the charging system? (battery, stator and VR).

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I don't think you're wrong, no. Wiring and/or a connection issue somewhere along the route, is about all that's left

BombardierBomb said:

I don't think you're wrong, no. Wiring and/or a connection issue somewhere along the route, is about all that's left

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Thank you
If the rain holds off, I hope to get into that on the weekend....hopefully. But now I'm self-doubting. I'll also recheck the stator. Do you know if I can pop off the connector on the VR with the 3 wires and run it to check for AC voltage coming into the VR?

Rocketdog said:

Yes, you can check the AC voltage coming from the stator using the Dynamic test. .
View attachment 111856

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Thank you !
Have to say that some days my brain is as sharp as a tack, others...not so much. This is a "not so much' day. I did that exact dynamic test and got the voltages needed over different rpm's. For some reason I was thinking that the numbers might be different if I checked the same wires up the line further to the VR. Key words..."same wires". It was a duh moment. But I do appreciate your input, ..thank you!
Mind you, that would tell me if there was a bad connection or break in the line between the stator and VR. I suppose I could get that diagnosis from an ohm meter too.

I appreciate yours, and everyone's, input in trying to help a fella with a problem. It's a good atmosphere in here.

Rocketdog said:

Did you happen to check the charging system fuse (#4)?

Also take a look at #3.
View attachment 111859

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Funny you mentioned the fuse, Rocketdog. I was going through the manual and saw there were fuses there. I had that compartment open before and didn't see any. Turns out they were tucked under the plastics out of sight. And sure enough, I found that the 30A fuse was indeed blown. Replaced it ... started the wheeler, and wouldn't ya know it, charging at 14.5V. Not gonna lie, may have been a small trickle of liquid falling from one of my eyes,... or could have been the wind..lol.
So, my assumption is that the VR failed and burnt the fuse to protect the battery. Ingenious !! lol...
Thank you Rocketdog !

Final Update
Wheeler is fixed and running like it should !!
Again, to Rocketdog, Bombardierbomb and Deuce who helped walk me through this electrical/mechanical journey, from the bottom of my heart, THANK YOU !!
With the information I've learned in this forum, I hope I can pass it along to someone some day.
Thanks Guys !! Cheers !!

((I'm sure I'll be back, as my rig IS 18 years old ... ))