GTX DI Maintenance light / voltage issues

[sagent]

So I have been having maintenance light issues with my 01 GTX DI since i bought it. Light & message would come on every once in while while riding but would not go into limp mode. Last week purchased a candoo pro and there where about half of all the fault codes set in the computer. I purchased a new heavy duty 4-tec rectifier from OSD parts thinking a had voltage issues as it appeared it would charge over 15 volts when revving motor. New rectifier is in and took it out last weekend. Ran fine for the first couple of runs and then sunday the maintenance light started showing up again but only when i got on he throttle. When i let it idle down it was fine. The machine seems to run fine. It appears the only code that showed back up since I installed the rectifier was a P0536 "voltage too high" code. Just hooked it up to the candoo pro again and revved the motor and it appeared the voltage again got into the 15 volt range for a second or two. Any ideas on what may be the problem ?

 

[Dr Honda]

I'm guessing the new rectifier isn't good. I've seen it a lot of times with the "Import" parts.

 

[sagent]

So I tested the three magneto wires going into rectifier and all were in the range of 0.5-0.8 ohms. Also tested all three for shorts to ground and all tested ok. According to the manual stator should be ok right ? The only thing left would be bad rectifier correct ? Code was actually P0563 and did come back up as active again this past weekend

 

[jhjesse]

P0563 is "Battery voltage high" warning. Causes are: "Battery failure, rectifier failure, battery terminal connection."

Hope this helps.

 

[sagent]

Well decided to try another rectifier from amazon. Took the machine out and ran it a few times. After the third run was going across the lake at full speed and maintenance light came on and went into limp mode with the beeps. Took it back and candoo pro now says battery voltage low code. I put back in the OSD rectifier and machine runs fine but maintenance light still on & battery voltage high code. Any ideas what is going on ? I have another OSD rectifier I will try this weekend.

 

[68ragtop]

DI's draw big amperage compared to other engines. Personally I wouldn't waste my money on aftermarket R/R's, especially on a DI. they are way to sensitive on operating voltage range & yet demand a lot of power. The 4-tec R/R is a great upgrade. I have omen in my RXDI. But, it really needs to be an oem unit IMO.

 

[sagent]

Well, hooked up my meter to the battery and took it out for a ride. Voltage holds at abt 14 volts until you hit about 5200 rpm. Climbs to about 17-18 volts at wide open throttle. Tried a third rectifier and same thing. Any Ideas ?

 

[Geeps2900]

Hi, I'm having the exact same issue. I've gone through two rectifiers already and I ordered a third. I've checked all my wires to the magneto and they are all fine. I've cleaned my grounds as I've read this can put a big load on the rectifier. Have you found a solution?

 

[Mekanix]

If its not the stator shorting out while under running conditions I'd look for intermittent connections from the rectifyer to ground and then from ground to engine and then from engine to battery.

Or while running and getting the higher voltage, measure from the regulator ground to the engine ground and then from the regulator to the battery negative. Anything above 0.5V is a sign there is a problem.

 

[Geeps2900]

Thanks for the help Stephen. My grounds should all be good, especially after I took them apart and cleaned all the corrosion off. I even cleaned the positive battery wire and both posts on the battery. But I only did this after running both rectifiers very hot. The Stator appears to work fine when the rpm is high because it is giving me about 50 or more volts AC. As for your last tests, wouldn't those just confirm that the rectifier is bad? I've static tested the rectifiers based on a test on YouTube using resistance and they both fail the test showing resistance on all combination of wires. I'm wondering if I missed anything before I try a third rectifier on the cleaned off grounds, I don't want to fry another one.

 

[Geeps2900]

OK, just to let anyone who stumbles onto this thread, I cleaned all my battery connections and the little black ground that connects to the battery ground. I checked all my other connections at the MPEM to make sure they were nice and clean. I also polished off the fuse connections but I'm not sure if that made any difference. I bought and installed a new rectifier after cleaning all the grounds. I ran my RX DI and checked the rectifier. It was hot after just a few minutes of riding (5 to 10 minutes), but I found out that is normal. I subsequently took it out for longer rides and the red light problem hasn't happened yet. So just to say if you're blowing rectifiers, just clean your grounds carefully, then install a new rectifier.

 

[statikuz]

I award you 10 internet points for adding an explanation rather than saying

fixed thx

 

[Coastiejoe]

Thanks for posting your solution,,,


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