354 charging system problem
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Thread: 354 charging system problem

  1. #1
    Junior Member
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    354 charging system problem

    Hi hope somebody can help . My 1980 354 isn't charging, fitted a new Regulator, Rectifier, alternator was sent to specialists for check repair. Battery is new. All other elements of electrics working ( I.e. lights, indicators, starter, engine runs etc.) Switch ignition on and ignition/ charging light doesn't light up. ( bulb ok) I am out of ideas any body help with some constructive advice.

  2. #2
    Senior Member
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    Mark Hollingsworth
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    If the rest of the components are good, I suspect wiring/connectors. Heavy on the connectors.
    Did the 354 still have those phoney ‘pointy end fuses’? I had nothing but trouble with those. Suggest modern fusebox (if not already done).

    Mark
    1978 Benelli sei, 1973 Benelli 250 SuperSport, 1968 Benelli Dynamo Trail, various OSSAs, Betas

  3. #3
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    Hi Mark thanks for your reply, part of the work I have completed on the bike was to renew the fuse box. Although it does have those "bullet " type fuses the are all new along with all other parts of the electrical system seem to work correctly. I will refocus on all of the terminals within the charging circuit. Any other thoughts or guidance will be very helpful

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  5. #4
    Senior Member DenH's Avatar
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    DENIS
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    I had problems with charging system on an old suzuki.turned out to be bad earth connections.
    when i was young i was very indecisive,now im older im not so sure.

  6. #5
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    Whoever the company did the electrical on these was paid by the foot or meter. And the Itialians beeing handsy people need lots of thumb switches to keep busy. On my 254 the lower left 3 way has to be right or it won't run. I think its a parking light? There is so much wiring the fuel tank will only fit if harness are tucked in just right. Much of it runs back and forth headlight to battery to connect inches from where it started. I did have a short in rear brake switch, disconnect to fix. Starter and charging wires zig zag behind clutch lever on motor. I tape fixed some bad insulation there. Was oil soaked from seal for starter. If the seal is pushed in flush the lip rides on smaller diameter. I push it halfway so starter seats it and no leak. My starter also was shorted, spring wedged under brush guide in a way that could only happen by uncrimping and take apart like I did to fix. A true Houdini mystery of the universe for me I will never understand. I used a lathe to cut the crimp. Short pieces of aluminum tape smoothed tightly with piece of plastic under thumb to hold brushplate. 3 or 4 layers and fine for years. i had to open again once to spray clean oil out off brushes

  7. #6
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    is this a rebuild? Was the bike runing and charging recently??
    Why do it? because we can and we want to! ( Domenico Benelli, when asked why the had spent so many years profits on the pursuit of world titles)

  8. #7
    Member Cosmo's Avatar
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    Cosmos
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    The Benelli 4's are rather different from the otherwise very similar Honda 500/550's systems. The Benellis have sprung carbon brush pick ups off the rotor, so go back to basics. Check those first and if ok, unclip the block connection off the generator and check those connections too. Also follow those up to the rectifier box under the side panel and check the spade connectors, see if you're getting current off the phases when running. If so follow the cables through the loom to the voltage regulator. That's a Bosch mechanical one - not waterproof so they commonly corrode inside, so see if that's a failure. You might also have a broken wire somewhere, so go through section by section. Perseverance and a methodological approach will find the issue. Good hunting.
    Just saw you've changed the regulator, wiring or connections are probably the culprits.
    Last edited by Cosmo; Today at 03:21 PM.

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