I bought the bike in April and replaced the battery from the suggestion of the previous owner. and was able to travel around for about 200km before I started having an issue with the Bike dying on me, even with it revved aa little bit higher than normal. After taking it to the shop they said the voltage regulator/rectifier went, so the replaced that and I was on my way. I did a 30min drive, filled up then went to start it and it was dead, I bump started it and drove an 1.5 hours at 120km/h. again I went to start my bike to return home and it was dead. after taking it to the shop a 2nd time they told me my volt regulator/rectifier was burnt out a second time. They thought wiring was bad, so I took it home and traced the wiring, checked the connections and grounds and all seemed fine. I brought it back to them and they confirmed the wiring was fine. The shop then assumed the stator was bad, so the replaced that a couple times but it was still not putting out enough power to what it should be. The next part they thought it might be is the counter part to the stator. and thats the current spot where it is sitting. Do you have any suggestions of what could be wrong and what I can do to remedy this issue?
Hi,
I've seen additional earth wires fitted to the regulators on the Suzuki 550 series of bikes. From what I can gather the regulator is mounted on a frame near the battery. The bike I owned had another earth wire added which earthed the regulator to the main frame. A small length of wire and a couple of eyelet terminals at either end is all that was used on the bike I had. I know that the 550's did have a reputation for regulator faults but you seem to have tried the usual cures. I hope you get it sorted.
You have replaced the battery, the rect/reg twice and the stator twice. Wiring is thought to be OK the only part not checked is the magnetic rotor. These rarely go wrong, to see if it is showing a strong magnetic force try putting a screwdriver blade near it.
Some bikes used to have brushes in the alternator similar to a car set up these can cause problems if worn or loose. If yours is a 2 part (air gap) alternator having just the rotor and stator try this. Unplug the alternator connector that links to the reg/rect. Get a multimeter and set to continuity ohms find a good earth point on the bike and connect the black meter lead to it touch the red lead to each contact in the alternator connector in turn if you get no reading or buzz from the meter the stator is OK. I would then look at the battery. Make sure the battery is able to be charged, do not use a car charger ever, you need a charger that is for motorcycle use only, less than 1 amp output. Never try to jump start the bike from another vehicle, when removing the battery disconnect negative first when fitting the battery connect positive first. Good luck.
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Luke, did you ever get this resolved? I am having the exact same issue with my GS850 1980, and i believe it it the magnetic rotor that has possibly become de-magnitized, I've checked everything else, bought new stator and rec/reg from ricks motorsports, new battery. checked stator out put wires, 2 are putting out 25V AC at idle, one is 5V (not enough) plz help if you can? 309219fourfour75 is my mobile
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