Smoke and fire at Voltage regulator

[Threwithu]

So let me preface this with the fact that I have had starting issues in the past due to the power cable bolt to the starter loosening over time with road vibration causing the bike to not start even on a full battery. the bolt and power cable becoming extremely hot to the point of burning the rubber boot

Yesterday not having ridden for a few days decided to take the bike out for a small spin. The weather was about 68 degrees so when I took it off the battery tender and rolled out of the garage, the bike was just not starting and loosing cranking amps. Decided to give it a jump from a 12 volt non runningcar battery and it started right up. Drove it about 2 miles when I noticed smoke coming from the front of the bike. I pulled over quickly into a gas station (wrong place to pull over with possible fire issues) and turned bike off. Smoke become worse and a small fire started in the front right under the voltage regulator. Got some water and put it out. Noticed that the wire coming out of the voltage regulator and going back to the battery/EHC area had burned completely through the wire/flame retardant cover and had started right at the Voltage regulator wire opening, which was now bear and touching the frame. Moved it from the frame and was able to start the bike and get it the 2 miles home. Once home I noticed the lightly loose power bolt to the starter which explain the difficulty in starting, but cant figure out why the wire go so hot to burn through. Any and all ideas appreciated and welcome

 

[bigkelk9]

So let me preface this with the fact that I have had starting issues in the past due to the power cable bolt to the starter loosening over time with road vibration causing the bike to not start even on a full battery. the bolt and power cable becoming extremely hot to the point of burning the rubber boot

Yesterday not having ridden for a few days decided to take the bike out for a small spin. The weather was about 68 degrees so when I took it off the battery tender and rolled out of the garage, the bike was just not starting and loosing cranking amps. Decided to give it a jump from a 12 volt non runningcar battery and it started right up. Drove it about 2 miles when I noticed smoke coming from the front of the bike. I pulled over quickly into a gas station (wrong place to pull over with possible fire issues) and turned bike off. Smoke become worse and a small fire started in the front right under the voltage regulator. Got some water and put it out. Noticed that the wire coming out of the voltage regulator and going back to the battery/EHC area had burned completely through the wire/flame retardant cover and had started right at the Voltage regulator wire opening, which was now bear and touching the frame. Moved it from the frame and was able to start the bike and get it the 2 miles home. Once home I noticed the lightly loose power bolt to the starter which explain the difficulty in starting, but cant figure out why the wire go so hot to burn through. Any and all ideas appreciated and welcome

Previous experience.. if the battery cable is loose or the ground to starter is loose it will melt the battery terminal.. so not uncommon... exposed wire arching on frame will do the same.. recheck all wires and bolts

 

[cdogg556]

The original voltage regulators were known to go up in flames, I had the same thing happen to me, I was riding and thought I was smelling my brake pads burning, pulled in my driveway and the front of my bike was on fire! Come to find out this is a common problem with the stock VR, mine also melted the wires to the frame, I installed a new VR and eventually replaced my EHC with an ESC from Deadone Custom's and have had no issues since, that was over a year and a half ago and over 8,000 miles. Get a upgraded VR from Curtis and make sure all connections are "clean and tight" and you should be good to go, good luck.

 

[Threwithu]

The original voltage regulators were known to go up in flames, I had the same thing happen to me, I was riding and thought I was smelling my brake pads burning, pulled in my driveway and the front of my bike was on fire! Come to find out this is a common problem with the stock VR, mine also melted the wires to the frame, I installed a new VR and eventually replaced my EHC with an ESC from Deadone Custom's and have had no issues since, that was over a year and a half ago and over 8,000 miles. Get a upgraded VR from Curtis and make sure all connections are "clean and tight" and you should be good to go, good luck.

Curtis?? How did you rewire the melted wires? The 2 wire hat go from the VR and go the stator plug our fine. Where does the wire go heading back to the battery area. followed it almost all the way, but not sure?

 

[cdogg556]

https://www.wildsteedworx.com
The new VR come with all the wires, the wire that melted goes to a breaker mounted on your battery box.

 

[Threwithu]

https://www.wildsteedworx.com
The new VR come with all the wires, the wire that melted goes to a breaker mounted on your battery box.

Great. How can I contact Curtis?

 

[Threwithu]

Great. How can I contact Curtis?[/QUOT
Just saw the ink thank you

 

[cdogg556]

The link in the last post,https://www.wildsteedworx.com

 

[cdogg556]

http://www.wildsteedworx.com/index.php?main_page=index&cPath=65_68_173_82_281

 

[Mr. Wright]

Go ahead and order the 40 amp system. you won't regret it.

 

[Mickeetwo]

It was 2007 when they had the recall. You could drop the VR and check the part numbers. Was discussed on bigdogbiker back then....heres the link http://www.bigdogbiker.com/threads/voltage-regulator-recall.454/

 

[TapioK]

Huh, sounds like the wires from VR shorted near the battery, that would melt the wires and the stupid fuse does nothing to prevent that. The start of the chain reaction may well be faulty VR pushing 19+ volts. If that is the case you are lucky you didn't burn the EHC. Now you should go thru all the other wires to make sure there is no more burned wires waiting to short out. Seems you might be lucky enough and your battery was able to steady the current to manageable level. Huh!
Or this is all BS and I was wrong again


Sent from my iPhone using Tapatalk

 

[Threwithu]

Go ahead and order the 40 amp system. you won't regret it.

Looks like wild steed only has the 32 amps in stock, tried calling but got a message saying to email..any other sourses

 

[Threwithu]

Huh, sounds like the wires from VR shorted near the battery, that would melt the wires and the stupid fuse does nothing to prevent that. The start of the chain reaction may well be faulty VR pushing 19+ volts. If that is the case you are lucky you didn't burn the EHC. Now you should go thru all the other wires to make sure there is no more burned wires waiting to short out. Seems you might be lucky enough and your battery was able to steady the current to manageable level. Huh!
Or this is all BS and I was wrong again


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Actually they shorted , smoked and burned near the VR. Yes Im lucky I didn't short anything out that I know of as yet

 

[Threwithu]

It was 2007 when they had the recall. You could drop the VR and check the part numbers. Was discussed on bigdogbiker back then....heres the link http://www.bigdogbiker.com/threads/voltage-regulator-recall.454/

I have a 05 but the VR has an 03..could that be correct?

 

[Threwithu]

As you can see the fire occurred at the back near were the the other wires going back to the battery are located (Pic 1 left side). Those burned up, while the ones t the stator did not.

 

[Threwithu]

Lastly it looks like this VR has only 3 wires (see above), while the new 32 amp have four wires and in the install instructions says to wire to the battery terminal, but the current one is bolted to the circuit breaker. So i am guessing the VR fourth wire is a ground?

 

[Th3InfamousI]

Lastly it looks like this VR has only 3 wires (see above), while the new 32 amp have four wires and in the install instructions says to wire to the battery terminal, but the current one is bolted to the circuit breaker. So i am guessing the VR fourth wire is a ground?

Should be 4 ... Where's your ground on the fried one? Should be grounded to at least the mounting bolt holding it on the frame.

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[Mr. Wright]

Looks like wild steed only has the 32 amps in stock, tried calling but got a message saying to email..any other sourses

I just got a 40 amp from him, and yes, e-mail is the fastest way to get ahold of him.
If you go with the 40 amp, you will need the instructions on this thread.
http://www.bigdogbiker.com/threads/how-to-charging-system-upgrade-40-amp-3-phase.7511/

 

[Mr. Wright]

Should be 4 ... Where's your ground on the fried one? Should be grounded to at least the mounting bolt holding it on the frame.

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I believe the 05's were grounded through the casing, and was probably the reason they had a problem shorting out.