I'm reviving an old Yamaha XV535 Virago. It's running and passed roadworthy inspection yesterday, but it has one remaining issue before I take it for a real ride - its not charging enough. Battery voltage increases from ~12.5V to ~12.9V when I start it. Should be ~14V.
A lot of the electrical connections were very crusty - I've cleaned them as best I can with contact cleaner and mechanical scraping. The 4 pin connector from the pickup coils to the loom was particularly nasty and has been hot and I could not clean it enough so replaced it with a (knock-off) Deutsch DT connector and that's working well. The connector from the stator to the loom has also been hot. I've replaced the plastic shells and cleaned the connectors as best I can but I feel this connector may still be the source of my low charging voltage and I plan to replace it.
My options are 3 x generic bullet connectors or a single 3 (solid) pin Deutsch DT.
I know the DT connectors are not intended for "power" applications, but I can't find anything to say if the current on each of these wires from the stator would exceed the ~7.5A they are supposed to be rated for.
Thoughts?
It's hard to measure the resistance of the connection as they're corroded and messy in the back as well - but I think I can get a 0 ohm reading from each.
I just measured the stator (I know, should have done it ages ago) and have ~35-55V on all pairs.
Double checked the battery - the 12.4V static drops to 11.3V running with the stator disconnected but increases to 12.9V with the stator connected. It's not perfect, but it's working. I'm just going to ride and see how it works out.
If your battery is at 12.4V resting, then it's no good. Charge the battery fully, then let it rest for 24 hours. The voltage should be around 12.8. The lower the resting voltage, the worse the battery's condition, and the more it will tax your charging system.
The bike hasn't been seriously ridden yet and the battery has been cranking the engine a lot while trying to diagnose issues. I'm happy that it still at 12.4 - but I understand what you're saying.