Over charge issue

[doubletrouble]

Finally was able to get back at this. I put the original reg/rec back in the bike. While doing so I noticed that one of the "2 into 1" connections next to the rec was broken. I had to use a butt connector to put the 3 wires back together but, now the bike won't start. She cranks, I smell gas, it even backfired twice but she won't start. See the pic to see what connector I'm talking about. I'm not the greatest at electrical so if something don't look right please help. Thanks.

[gltriker]

She cranks, I smell gas, it even backfired twice but she won't start.

The engine Backfires because you have both primary leads from the breaker points' ignition baseplate plugged into the same connector!
one of the 2 ignition coils is simultaneously receiving info from both sets of points (or both DYNA modules)
I presume you still have points because the condenser is still in place.
anyway....
there is another, identical, wire connector that wants its own color matched primary wire plugged into it, too!

Another observation....that is a worrisome looking ground cable assembly, too.

[Track T 2411]

you have both primary leads from the points ignition plugged into the same connector!

there is another, identical, wire connector that wants its own color matched wire plugged into it, too!

That's what I thought, as well, but I'm not as versed in the 1000's wiring...

[doubletrouble]

I have the points condenser wiring back where it should be, bike starts and runs now.
Put a ground wire on the mounting bolt to the neg bat post (back to original reg/rec now also) and she is charging at 15.3v at 3000 rpm. Still over charging. Should I consider removing the battery box and cleaning the mounting surfaces on that now? Any other ideas?
Thanks!

[Sidecar Bob]

Its been several years since I switched them

If it has been working correctly for several years it is unlikely that the way you connected the new reg/rec is the problem.

Check the voltage with a different meter. The FSM says it should be 14-15V; 15.3 is only 2% out of that range and I've seen meters that were out by a lot more than 2%.

[tlbranth]

Sounds way high to me. Can't argue with the shop manual, though, if that's what it specifies but I'd like to see 14-14.3.
Make sure that sensing wire has a good battery connection. If there's resistance, the regulator will jack up the voltage output to compensate.

[Sidecar Bob]

Yep. If a second meter verifies that it is high definitely check the connections.

[doubletrouble]

I forgot to mention, I did check the voltage on the sensing wire. It was at 14.8v while the battery voltage was reading 15.3v.
I will try a different meter to verify.

[Sidecar Bob]

Sounds like a bad connection (or several) somewhere between the battery and the sense wire.

[CYBORG]

All this conversation, and no one has asked what type of battery we are talking about. From the picture I see, it seems to be a Harley sealed battery, But can't tell if it is glass mat or what. I think the type of battery is important information as to weather it is actually being over charged. While charging, does The battery feel hot to the touch? Are the sides bulging out? I would be sure the lights are on, and even engage the brake light While checking the voltage. And a good meter is very Important to an accurate reading

[CYBORG]

and be sure all connections are clean and tight.

[CYBORG]

On that note, I think I would replace, or at least clean real good, the neg. cable. And clean both ends where it connects to the battery and frame. nd while the cable is loose check the resistance of the cable itself

[Sidecar Bob]

Any lead acid battery should require the same charge voltage, whether it is flooded cell, AGM or gel cell. LiIon and other types may need something different...

But unless the battery is something strange that produces 15V, the charging system voltage will normally be higher than the battery voltage (that's how you get current to flow into the battery to charge it) so the problem has to be in the charging system and not related to the battery type.

[CYBORG]

Any lead acid battery should require the same charge voltage, whether it is flooded cell, AGM or gel cell. LiIon and other types may need something different...

But unless the battery is something strange that produces 15V, the charging system voltage will normally be higher than the battery voltage (that's how you get current to flow into the battery to charge it) so the problem has to be in the charging system and not related to the battery type.

As always I respect your input, and agree with you. But must add that the wiring I see in the picture needs some serious attention, which I think can't hurt the outcome of charging the battery

[Sidecar Bob]

No doubt about that.

Edit: Hey, I just realized that this is my 4400th post