Stator and wiring burn out ? - GS 550et 1980

[ukjules]

I thought the rectifier and regulator were the same.
I have the proper service manual but alas not where I am.... Haynes only here .
I know the regulator or whatever it is is ok as works on the gsx. Iv replaced the stator and regulator or whatever that is.

- I will try and find where what rectifier is.
- will look for basscliff website
- assure myself that there are only ,4 fuses on this bike under rh side panel . They are all ok

I'll check wiring this eve. Buy a crate of beer then search for what you suggest and implement . It is noted and will be done !!

!reading page 124 - now

[ukjules]

Ok - I will have to do the workshop manual tests another time. Very hard to understand and pics so bad. I'll have to get my copy.
BUT
I have a checklist from.net of what to test.

- the reg tests ok in these tests. The reg works on another bike so let's assume it's ok.
- the test tells me that there is a bad connection in the positive lead from the reg to battery positive terminal.
Says to check this connection all the way through.
I don't know where this wire goes ? Buzz tests ok from wire to battery positive wire connection.

This test involved letting the engine idle and connecting the black neg multimeter lead to the positive battery terminal. And connecting the red multimeter lead to the red reg output wire.
States if it is less than 0.2 volts all is okay.
Mine showed 0.45 volts so a fail.

A buzz test from reg loom POS wire to battery positive cable shows a connection

[ukjules]

I am way out.of my league here.

It has to be wiring ?
How do I check wiring ? I don't know the path of he wire to the Reg ?

[ukjules]

This is what tesg sequence says is wrong

[ukjules]

Also I'm trying to find / understand the units on this multimeter.

I was testing ac volts setting 200 on mm.
It registered 0.5.
What does that mean ?
If it is 0.5 volts it means the new stator I put in is faulty as it had to be over ,50v.
As per this test - attached.

[ukjules]

P s the reg and rect must be one unit on my bike !!

[tom203]

Use a jumper wire from positive rectifier output to positive battery terminal…..and see if output compares to how rectifier behaved on other bike. The internal harness connection could have been smoked during your wiring misadventures.

[ukjules]

Ok. I'm afraid your gonna have to be very specific.
What am I checking volts DC or AC , ohms ?

I don't think I can give more stats !
The GSX is 8miles away from where I am.
Do you want the reg fully connected on this test ?

I am beginning to think I know what you mean. You mean to : from reg ,-
Wire as normal to stator - 3 wires
Neg wire to earth as normal
Pos wire direct to positive battery terminal which ignores the loom ? Hence revealing if wires fried?

Is that it ?
Can a reg be wired.like this full time ?

[ukjules]

I'll try what you say tomorrow . I like the logic !
Remember I am the worst at elecs as red green colour blind and have always struggled with this !!

Wiring a trailer up to my car almost have me a mental breakdown . But I did it after two weeks of grind with no help using a light bulb to test function ....

Advice appreciated by all !

[pdqford]

I am way out.of my league here.

It has to be wiring ?
How do I check wiring ? I don't know the path of he wire to the Reg ?

Here is how to measure the voltage dropped in your wiring loom between the regulator output and the battery positive post:
(You don't have to know the exact route through the wiring loom to measure the voltage dropped in that circuit.)

To measure voltage dropped in that circuit there must be current flowing through the circuit so you need to have the bike running.

With your meter set to DC voltage and the 20 volt scale.
Place the positive probe of your meter to the red wire coming out of the regulator.
Place the negative probe of your meter to the positive battery post.

Your meter is now creating an alternate route from the regulator output to the battery post.
And your meter will now display the voltage that your wring loom couldn't handle (i.e. volage dropped) because of resistance in the wiring loom.

You should like to see no more than 0.3 to 0.4volts dropped.in the circuit.

(If more than then 0.5volts is dropped, THEN you need to know the exact route through the wiring loom so you can use your meter to similarly test for voltage drop in each segment of the path through the wiring loom to find the culprit(s) ,)

Hope this helps........

[ukjules]

Update - status
Yes info given does help ! I can just about understand it.
So I need to do the following,:

- voltage drop test from.pos red wire from regulator to the POS battery terminal with bike running.
I assume.the voltage drop is whatever the result is minus the voltage between battery pods s and neg posts .

- temporarily wire the pos terminal of regulator directly to the POS battery terminal (which if it is faulty wiring ) could show charging of battery when bike running. I.e test charging in this setup.

Will post results today as it seems this will get 'us' somewhere.

[ukjules]

Voltage drop test result:
(With known working reg from.my GSX)
Between reg output and battery positive.

Static battery - 12.71v

Leads on as described / bike not running :
9.97v

Bike running leads on as described - 9.55v

So voltage drop = 3.6v
Note this works fine on my GSX but is a small regulator for that bike.

[ukjules]

Using gsx regulator:
Wiring reg output direct to bikes battery terminal.
(This with known working reg and the new stator)

Still not charging !
No increase in volts on battery with revs.

Using original regulator when I caused issue:
Battery voltage - 12.71v
Voltage on leads POS reg to pos battery -0v
As above but bike running - 0v
Clearly this must have blown ? Although tests fine bench testing !!!

Using new regulator :
Battery voltage - 12.7 v
Voltage on leads POS reg to pos battery -12.4v
As above but bike running 12.07v
Voltage drop - 0.65v

Connecting reg POS direct to battery pos - still won't show charge.


I am now stuck. Wiring issue but how as I've removed that section ?

Couod it be the new stator ? Again worked with basic bench tests ? But fails on one new test I showed past posts ??

And note I put this very battery on my GSX and it does accept charge.

I am totally stumped and cannot understand how what I did caused this after renewing everything .

But yes I need to test the wiring through the loom.
How in gods name do i do that.
Is it tank off and get stuck in ? Coloured wiring diagrams don't help me.much....

I'll let you guys digest this , add anything and I will consider trying to voltage drop test the entire route if the reg loom output wire ....

[pdqford]

That wiring diagram you attached is too tough for me to read
(With my iPad I used to be able to "unpinch" a diagram to expand it but they won't let my iPad access GSResources any more..)

I can only suggest that you go to BileCliff's web site and see the factory service manual here:

GS550_77-82_all.pdf (bwringer.com)

I don't know if the UK models were different, but if you go to :

pg 124-129 for testing the charging system with separate rectifier and regulator units..
pg 158-159 for the wiring diagram for that system.

or

pg 191-195 for testing the charging system with integrated rectifier/regulator.
pg 158-159 for the wiring diagram for the intigrated system.

Hope you get it solved.

[ukjules]

I have a clear image but it's 4mb so can't put on here as 2mb max. This from a Haynes and barely useable.

The testing is done !!!!!!!
All analysis on here.

I now it seems have to trace the wire in the loom where there is a fault it seems .

I await for help ..... As I can't do this . But can be the person onsite to do what's needed.

I will however check page 191 and the diagram on 158.