Electrical Problems with 2005 RX Warrior

[skene]

Hey all,

I've been having some major problems with my electrical ever since I purchased my Warrior last december. I've had to replace 2 batteries, the stator, a rectifier last winter and this winter my CDI box shorted out. I replaced all these parts and it was running great. But three days ago my new rectifier catches fire and shorts out the man relay 30 amp fuse and leaves me in the bush.

My question is; has anyone else had or heard of the warrior editions having major electrical problems with shorts? overheating? or just faulty parts? The self diagnostic on the sled indicated a voltage problem but I'm not sure if its too much voltage or too little.
My father in law has been running a RX-1 2004 and has had zero problems.

Any ideas?

Thanks

Skene

 

[Sasquatch]

Hmmm as I told Rob I never heard of those kind of problems before. Maybe someone on here can help. What would cause a voltage problem is beyond my knowledge! The rectifier changes AC to DC I think but I don't know what controls voltage.

Before an admin get on ya you have to fill in your location. Site rules.

 

[Sasquatch]

Hey I posted a link to this over in the electrical section for you! Some good heads over there might be able to help.

 

[DV8]

The rectifier / regulator are together in the newer sleds, the rectifier changes the A/C to DC and the regulator controls the voltage so it doesnt go to high and fry components/ to much to battery.
I have a warrior and have only had the hand warmer gauge in the speedo stop working.

The recitifier usually send excess voltage to ground, so if you have a bad ground or grounds that could be a issue. Also check the harness in the front of sled for rub thoughs or chaffed wires that could ground out or short.
Does the sled have lots of corrosion? Green stuff on electrical connections?

 

[aVenture]

wow.... what a story.....

My take on all this would be the starter relay is closing at time.

Could it be that the starter lock in then generate back emf into your electrical circuit.....??? could just be it. That would overvoltage more sensible parts like the CDI or the regulator....which is not built to protect itself in this direction.

Hey..... we are talking of a cooked 30 amp so think big.

 

[aVenture]

...and yes, thinking about it, there was few similar issues with early RS chassis. You might search for this in the RS area, i recall that at some point dealers were blaming the knife style key holder. One guy even came up wiring a LED on the dash panel to report an energized starter.

Do you happen to have home made power take off connections behind the ignition switch ?

Anycase, good luck.

 

[Len Todd]

I would inspect all wiring for chaffing. Start by the ECM and work your way back.

There were a few problems with the starter not disengaging after the start. But as I recall, that typically took the starter out, not the whole Charging System.

And if the problem was once cured by replacing all those components, and then it reoccurred, something other than the new components most-likely is the root cause. Thus, I would start looking at the wiring for chaffing, which is a common problem.