1982 gs850g charing problem - stator and recitifier replacment

[miyagi54]

Hi all,

I have a 82 gs850g, and I have been having charging problem. I have bought a replacement stator and rectifier and trying to replace them now.

However the connections do the not match with whats currently on the bike so I'm looking for some guidance on how to do it correctly.

Here is what was originally on the bike. Turns out one of the connectors had fallen off, not sure if its always been like that or it's fell lose over the last season.
old: http://imageshack.us/photo/my-images...rectifier.jpg/

The new rectifier has different connectors. they have bullet ends.
new: http://imageshack.us/photo/my-images...rectifier.jpg/

Here is the stator taken out.
old stator: http://imageshack.us/photo/my-images/845/oldstator.jpg/
old stator connection: http://imageshack.us/photo/my-images...nnections.jpg/

The new stator has bullet connectors as well, but as you can see from the last picture the last person that owned this bike previously just stripped the wires and used electrical tape to seal the ends. Do I cut off the bullet connectors and do the same?
new stator: http://imageshack.us/photo/my-images/856/newstator.jpg/

Help would be appreciated.

[Nessism]

It doesn't matter what kind of connectors you use, just so long as they are secure.

You want the three stator output wires to feed directly into the R/R. Bypass the factory wiring for reasons that I'm hesitant to repeat because they have been very well covered in other threads, now in the archives.

The R/R ground can go either direct to the battery negative post or to a solid frame ground point. Do not ground to the battery box as it doesn't provide a very secure ground path.

For the R/R positive, you can either go to the fuesbox like the factory wiring or get yourself a small accessory fuse receptical (20 A is plenty) and use that to take power to the battery.

From the looks of your photos that "old" R/R is fairly new. It may be perfectly fine, other than that terminal fell off. Wonder if the stator is likewise? If that stator has black output wires like I think it does that means it's aftermarket. You may be replacing good parts that were malfunctioning because of a wiring issue.

[BassCliff]

Greetings and Salutations!!

Hi Mr. miyagi54,

You'll find lots of GS850G goodness on my little website. Please stop by. I think you'll like it there.

Use the diagram below as a guideline. Depending you what r/r unit you have, you may not have a "sense" wire. Just get some new connectors and solder/crimp them on in place of the old bullet connectors. Make sure your entire wiring harness is clean, all the grounds, connectors, fuse box, everything in the headlight bucket to the tail light, etc.



See my website for stator and r/r replacement guides.

Anyway, let me dump a TON if information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Rebuild Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. Now let me roll out the welcome mat for you...



Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[miyagi54]

update. still need help

So finally got to putting the bike together. I went with the option of directly connecting to the r/r.

1) I didn't know what to do with the pass thru cable tho? The r/r that was on there before did not have this cable.

2) After putting my stator cover back on, I noticed that there was some epoxy putty on the bottom. Must have been from previous owner. I continued on hoping for the best. Took the bike out, it turns on, that's a good start at least. Still not sure if it's actually charging but time will tell. Rode got a 15 min ride, it was a bit choppy, but it evened out after warming up.

However, got to a friends place, went inside for a few mins. When I came out, there was oil pooling. After closer inspection, where i saw that epoxy, I could clearly see a steady drip of oil coming from the bottom screw.

I thought I didn't put in the gasket correctly, but, it doesn't look like it's leaking from the gasket but from the screw directly. I tried tightening it, but I'm afraid of over tightening and stripping it.

Any suggestions? New cover? New gasket? More epoxy putty?

http://imageshack.us/g/9/p6040036.jpg/

[Redman]

Thanks for photos.

Welcome to GSR.
Maybe put your location in user profile. (goto UserCP).

.....
1) I didn't know what to do with the pass thru cable tho? The r/r that was on there before did not have this cable......

Not certain what cable you are refereing to.

You said you were still not certain if was charging.
Do you have a multimeter (voltmeter)?
You will want to have a multimeter.

So.....
.....
Any suggestions? New cover? New gasket? More epoxy putty?

http://imageshack.us/g/9/p6040036.jpg/

That definatly looks like some sort of damage repair. Maybe best to post that in 'general maintence' section. Maybe Lots of guys dont look in the electrical section.

.

[miyagi54]

Redman, this is the wire I'm referring to.

http://imageshack.us/photo/my-images/851/newrectifier.jpg/

And thanks, I will repost in the maintenance section, thanks for the heads up.

[cableguy]

Tip for posting pics: instead of copying the URL link, copy and paste the IMG info and the pic will display directly in your post. Make sure to hit enter once or twice to separate them in the post.

Good luck with your bike

[miyagi54]

thx cable guy, didn't know you could do that.

[Nessism]

Tip for posting pics: instead of copying the URL link, copy and paste the IMG info and the pic will display directly in your post. Make sure to hit enter once or twice to separate them in the post.

Good luck with your bike

Image shack doesn't allow direct links like photobucket does.

[Nessism]

That black wire leaving the R/R is the ground. You need to take it to the battery or a solid frame ground point. Looks like the lead was split so you can go to the harness somewhere plus the battery, which is fine.

[miyagi54]

Hey nessim, there is actually a 6th wire that for some reason I didn't keep in the photo, but that 6th wire was a green wire, which I thought to be the ground, which I attached to the frame.

Should I recap this black end and ground it to the battery?

[Nessism]

Hey nessim, there is actually a 6th wire that for some reason I didn't keep in the photo, but that 6th wire was a green wire, which I thought to be the ground, which I attached to the frame.

Should I recap this black end and ground it to the battery?

If there is a green wire too then maybe that particular R/R has a sense wire. It's silly to guess so I suggest you get a proper wiring diagram for your R/R and then go from there.

[Matchless]

Hey nessim, there is actually a 6th wire that for some reason I didn't keep in the photo, but that 6th wire was a green wire, which I thought to be the ground, which I attached to the frame.

Should I recap this black end and ground it to the battery?

If it has a thinner black wire and a heavier green wire it is probably an ex Honda unit. Honda uses green as ground.
Then the green wire should ground to battery negative pole and the black wire is a sense wire which should go to a switched live, such as the brake switch.
Its the best to compare on the wiring diagrams and to use a multimeter as suggested.

Or just look at the diagram Basscliff gave a you a bit earlier in the thread - did you see that?

[miyagi54]

Hey matcheless, yes I believe it's a honda part, I bought it from duanage of this site. Heard it was a good replacement for the oem part, since the oem is known to go bad.

I currently have the green wired to chasis, should I extend the wire so it will reach the negative on the battery? And current the sense wire is just hanging loose. Will that cause any problems?

Thanks everyone for helping out this newb.

[Nessism]

And current the sense wire is just hanging loose. Will that cause any problems?

Thanks everyone for helping out this newb.

Please tell me you are joking.

Seriously man, Duane has a wiring diagram that goes with his parts. Have you looked at it?