Bogging down gsx250e after a mile always and stops

[Cipher]

My 550 spec is 75 VAC at 5000 rpm. Stator test is easy to do. Measure each leg and check to assure there's no shorting to ground.
An El cheapo voltmeter that you can monitor while riding would be helpful.

your description is classic gs undercharging.
oddly in spite of three oem reg/rect failures my stator works perfectly.
my compufire unit works perfectly.

[ukjules]

I'll do some tests on stator and coils tomorrow.

It simply cannot be the RR or the Battery.
I can put them both on GS and it would
work perfectly.

[ukjules]

Update:

This morning battery 12.7v. thus it should start bike. ignition only nothing else works.

- if I bridge solenoid terminals starts immediately no probs at all. As soon as I take of connection stops dead.

So this is a electrical issue ? What could cause that as there is no reason it should just stop ?

[ukjules]

Update:

Started too look at the plate that the RR, Solenoid and igniter etc sits on. It is also the earth to these items and rear lights indicators.

So re checked wires , cleaned , renewed some but noted the entire plate is only earthed to bodywork via a rusty / dirty tab. See picture.

This is clearly a bad earth possibility and a hopeless design.

So I have cleaned the tab and again it will stop but won't if I hold the tab firm to the bodywork.
So now I xan always start it if I hold the tab to the bodywork.

How on earth do I redesign that tab to work as an earth ?

[ukjules]

argh. I'll run a wire from plate to a good earth
that done ... again OK.
I'll test 1m around home as cannot ever have this issue 10mipes out again.

stator test with all working - 75vac on all combinations.

surely this must be a fix !!!

[Gorminrider]

Yes, that's a problem that might be peculiar to twins*. The ground on that plate that seems to be otherwise only attached to the airbox through insulating grommets. I don't know how they even ran out of the factory. What with fitting in new regulators and such I've lost the plot of whatever magic they were using so I ran a ground to the frame myself...

and, note-too-self, I mean to move the ill-fitting replacement R/R to the bottom of the battery box or elsewhere someday

[ukjules]

You got it !!! It is a mad design and I'm so glad
you noticed it.
I dare not run bike to shops (16m round trip) yet but will run 1m from home
in circuits for a while.

I cannot push that bike again for a long long time. The bike cracked me so many times but this has to be a fix.
It's logically what happened.

[ukjules]

Conclusion:

The final issue was indeed that mad design of a plate that holds RR, igniter and Solenoid with no secure earth.

Bike runs reliably now with working RR and running wire earthing plate to bike frame.

[Gorminrider]

Yay! That wasn't so bad was it? .. easier than your trouble with the signal generators? and now you have a new clutch cable and R/R as well!

[grcamna2]

Subscribed this is a great thread.

[Rob S.]

I cannot push that bike again for a long long time.

I was 57 and a mile from home when my 11E snapped the chain. It was mostly uphill, but the push home was quality alone time with Suzi.

A 250? A stroll in the park.