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Discussion Starter #1
I have a really strange problem... I bought a pretty trashed 2005 CBR600rr and had to replace a number of things on it thus far to make it road worthy. It is finally ride-able and looks pretty good but sometimes has this issue:

I can be cruising or going fast and occasionally it seems like the charging system just stops working because the bike starts studering, break light dims, the gauge cluster turns off and the bike just dies after a bit of a strugle and misfiring (as it is draining the last bits of energy from the battery).

I can park the bike, turn it off and on, push start it and everything returns to normal, the charging system is once again charging the battery and I can even stop the bike in say 5 min and start it normally using the starter.

At first I thought it was the voltage regulator, but it does not happen due to any heat or any bumper to bumper traffic.

I even clipped, cleaned and re-clipped every single connector I could find on the bike, and made sure the main ground point by the relay switches on the left was tight as well as the battery terminals.

What do you guys think is wrong?
 

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Discussion Starter #2
Also just to add, there is nothing aftermarket on the wiring side of things, no cut wires or anything and no PC.

Also this issue is VERY intermittent, it occurs maybe once every 4 rides with no describable pattern.
 

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sounds more electrical than mechanical. i'm guessing you've also replaced the battery?
 

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Discussion Starter #4
sounds more electrical than mechanical. i'm guessing you've also replaced the battery?
Yep, iv replaced the
-battery (new Duralast from autozone)
-voltage regulator (new ElectroSport regulator)
-stator (used OEM one)

Could the ElectroSport regulator be bad even though its brand new?
 

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Check all of the connections, chances are very high that one of them is loose or corroded.
 

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Discussion Starter #6
I wonder what cable it is, I swear I checked like all of them!

Can any of the relays on the left side by the intake go bad and cause this?

I think that is the side where the bike went down b4 I got it.
 

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I'm having the same trouble with my bike, 2005 RR, Mine is strictly for the track but the same problems.

Trailer the bike to the track, bike starts no problem, let the bike warm up, shut it off, no problem....

Session starts, bike starts up again, no problem, hit the track for 20min, come back to the pits, turn the bike off and it is dead next time i start it.

Now, if i let the bike idle for less than 5min once I get back to the pit, it'll start up for the next session no problem,

Now, I've had bikes not charge at a low RPM, but never not charge at a High RPM,

Any ideas anyone? or, does anyone have a recommendation on some kind of data logger so I can see what it is doing out on the track.
 

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I'm having the same trouble with my bike, 2005 RR, Mine is strictly for the track but the same problems.

Trailer the bike to the track, bike starts no problem, let the bike warm up, shut it off, no problem....

Session starts, bike starts up again, no problem, hit the track for 20min, come back to the pits, turn the bike off and it is dead next time i start it.

Now, if i let the bike idle for less than 5min once I get back to the pit, it'll start up for the next session no problem,

Now, I've had bikes not charge at a low RPM, but never not charge at a High RPM,

Any ideas anyone? or, does anyone have a recommendation on some kind of data logger so I can see what it is doing out on the track.
Let the bike idle for LESS THAN 5 mines or AT LEAST 5 mins?
(just clarifying)
 

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Ok, so:

Out on track, come back in and shut the bike off right away and it doesn't start later on

Out on track, come back in and let the bike idle then... 1. It shuts itself down before 5 mins is out OR 2. you let it idle for less than five minutes then you shut it down. - but either way the bike starts and runs just fine when it gets to idle...

Does it make any sort of sounds when it fails to start? Can you hear the starter motor? What about the fuel pump? Have you removed the BAS? How about the headlights? Power commander? Any other mods?
 

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Ok, so:

Out on track, come back in and shut the bike off right away and it doesn't start later on

Out on track, come back in and let the bike idle then... 1. It shuts itself down before 5 mins is out OR 2. you let it idle for less than five minutes then you shut it down. - but either way the bike starts and runs just fine when it gets to idle...

Does it make any sort of sounds when it fails to start? Can you hear the starter motor? What about the fuel pump? Have you removed the BAS? How about the headlights? Power commander? Any other mods?
Yes, on track, back in, turn the bike off and it doesn't start later

Out on track, back in, I LET the bike idle for less than 5 minutes, then I shut it off, next time i start it, it starts just fine.

When it fails to start it sounds just like a dead battery, I can push start it every time.

I can hear the fuel pump loud and clear, No lights, No BAS, Yes power commander and ignition module, No other electrical mods
 

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hmm...

Have you tested the charging system? If you have a good quality multimeter you may be able to measure the voltage and show both AC and DC. Most cheap multimeters will fail to read AC when there is a DC level present so you need to use one that is specifically designed to do so... I would be interested to know what numbers you get as it sounds like the higher rpm might be punching some AC into the bike...
 

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Discussion Starter #14
Rocketfish, your problem sounds very similar to mine, except mine goes the one step worse and actually dies sometimes.

What should the multimeter read? What is a good a simple guide for testing the charging system?
 

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I'm having the same trouble with my bike, 2005 RR, Mine is strictly for the track but the same problems.

Trailer the bike to the track, bike starts no problem, let the bike warm up, shut it off, no problem....

Session starts, bike starts up again, no problem, hit the track for 20min, come back to the pits, turn the bike off and it is dead next time i start it.

Now, if i let the bike idle for less than 5min once I get back to the pit, it'll start up for the next session no problem,

Now, I've had bikes not charge at a low RPM, but never not charge at a High RPM,

Any ideas anyone? or, does anyone have a recommendation on some kind of data logger so I can see what it is doing out on the track.
have you checked any voltages?

and for reference i had a similar problem with my street bike, if i rode it for any length of time, often it would just not start, was like the battery was totally dead

i *think* i have fixed that, by disassembling the starter motor, i found the brushes to be in spec, but there was a LOT of carbon in there, got rid of all of that, and the bike hasnt failed, or acted wrong yet ... and it only did this when the starter was hot

i was able to readily replicate the issue by idling the bike for extended periods ... get a lot of heat into the starter, kill the bike, and it would fail to restart ... spraying water onto the back of the clutch cover (where the starter is) cooling the starter, allowed me to restart the bike with no issue.
 

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well, if i don't go to the track tomorrow, i'm going to play around with it for a few... and if it rains at the track... I might mess with it there, we'll see...
 
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