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Old 9 Jun 2011
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XT600E electric issue! Flat battery

Hey guys!

I've recently came back to the island for some R&R...

I've repaired all the electric connections on my XT600E...
I soldered and used "shrinkwrap" on every connection I fiddled on so I could put all the electrics inside my fiberglass "airbox" and crimped those good terminals that have locking tabs on the every socket as I previously had only used those cheap ones that don't lock inside the sockets because I couldn't get any here in the island All so I could be 100% positive that the problem wasn't due from a bad connection!

So, to the point: recently my battery was going flat!

Everything was working good for a couple of months after I replaced the old regulator/rectifier that was toast!

I since repaired all the electrics as I mentioned above and found only ONE problem.

The cable that attaches the FUSE bulletconnector to the positive battery cable and crimped together with the battery cable end that attaches to the solenoid was hanging by only 3 very very very thin and corroded cores(from the multicore cable).

I believe this cable is the one keeping the battery always fully charged and therefore the flat battery was a consequence of it!

Is this correct?

I've replaced the fuse holder with one I bought off ebay UK and crimped a bulletconnector on one end (to attach to the electrics) and a "ring"terminal on the other end so it attaches on to the same solenoid terminal as the positive battery cable so they fit pressed together to "mimic" the original stock connection...

Will take a picture!

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Old 11 Jun 2011
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No one has an opinion on this?
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Old 11 Jun 2011
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I thought the battery was charged from the alternator not the solenoid? Picture will help.....if you did replace the wiring perhaps the battery is no longer good,does it hold a charge overnight and can you get a voltage drop reading when cranking the engine over,it should not drop to so low it wont start the engine...
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Old 11 Jun 2011
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battery is all good. It has been working very well like this since last november and I haven't ridden the bike from january to middle february and from march till now.

Right now I can't check anything as I don't have the left handside crankcase cover on as it's in the repair shop waiting to get fixed...

Since march I haven't used the bike and I should've charged her a bit before I went on to the mainland until last Sunday as it wouldn't crank the engine that well before I left.

Yesterday morning I checked the voltage and it only had 11.51volts on it.
I immediately put in on charge with the battery charger set at the low rating (0.85Amps) and left it for 7 hours.

It says on the battery sticker to charge in low rating (0.80 amps - not 0.85 as I mentioned above) from 5 to 10 hours.

As I said, I left it for 7hours at 0.85amps.

I've been checking the battery a few times today and also just checked her about 15minutes ago and the voltage is constant at 13.24v...

It's a bit high but it's constant and it's a gelled battery.

Keny: that is true! but that cable that comes from the alternator is the one with the fuse holder.

The stock fuse holder has two male bullet connectors, one on each end.

One of the male connectors goes to the cable coming from the alternator.
The other male bullet connector connects onto a female connector that is crimped together with the battery positive terminal that connects the battery to the solenoid.

This last one cable that haD the female bullet connector is the troublemaker...

Get it now?
I'll try to post the picture today afternoon after I wake up...
I'm too inebriated right now to use the camera loool

See you later
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Old 11 Jun 2011
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Good on you Vando,I ll wait for the picture when your sober.....
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Old 12 Jun 2011
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Theres a red wire going from the reg/rec to the plug at the starting relay. If this is disconnected (or damaged) you're battery wont charge.
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Old 14 Jun 2011
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pics pics:

It's the red wire I had on my hand.

That black thing that looks like a syringe cut in half is indeed what it looks like lol

It is IMPOSSIBLE to get a fuse to replace the original over here so I had to create my own "waterproof" fuse holder...

The red cable going to the right, after the fuse holder, is crimped to the thick red cable that connects to the solenoid (it's how it comes from factory).

That cable was only hanging by a couple of thin cores of wire!

Second picture is the new fuse holder.
I crimped a bullet male connector to one end and a ring-terminal to the other so I could connect it to the solenoid as seen in the picture.

Hope you guys understand what I just tried to explain..

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