R/R Overheating

[overheat]

I have converted an old junker gs into a gs bobber. Included in this was completely re-wiring the bike from scratch. However, I am running into a bit of a snag with the charging system. The only difference between the way I wired it and the way in the manual is I do not have a starter relay. Instead of going to the starter relay I connected the red wire directly to the battery. This caused my R/R to nearly light on fire. Next I tried hooking the red wire to the circuit breaker and it was a little bit better but still the R/R started to get hot. Any information as to why this is happening and why my R/R is overheating? Where do I need to connect to get power or is it even possible without running a starter relay? If you don't understand just ask and I will try to explain more clearly. Please, please, please help me. My project is so close to getting done! Thanks in advance!

[Steve]

First of all,


Not sure what "red wire" you connected straight to the battery, but the thing you are probably calling a "starter relay" (it's actually called a 'solenoid') is really necessary. That is, unless you have a real monster of a switch that can handle about 50 amps going through it.

What "circuit breaker" are you connecting to? There is none on a stock GS.

And, I will say this before everyone else chimes in, ... WHAT BIKE ARE YOU TALKING ABOUT???

It is considered to be a good idea to put your bike in your signature (does not have to be fancy, just say what it is) and put your location in your profile. There is likely someone that is close enough to help in person.

.

[SqDancerLynn1]

The regulator does need a good ground!!!

[BassCliff]

Greetings and Salutations!!

Hi Mr. overheat,

As Ms. Lynn suggests, your charging system needs good grounds and clean connections. The stock r/r units were a little on the puny side. There are several others that will fit our bikes and have more surface area for cooling and a greater capacity. What bike do you have?

Anyway, 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", the Carb Rebuild Series, and the Stator Papers. 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

[overheat]

I started with this...


And now I have this...

Steve: I know there is no circuit breaker on the stock system but I am running one so I do not need to have individual fuses.

Lynn: I had it grounded to the frame the first time and the second time I connected it to the ground on the battery.

Cliff: My bike is a 79 gs1100e. I should have no problem with the stock r/r as I am running just bare bones electrical on this bike.

Thanks for the replies but any ideas why the r/r would get so hot? Obviously it was getting too much power but I am not sure why or what to do.

[Planecrazy]

Stock Suzuki R/R's are famous for causing problems because of their small size ... One of the most popular mods is to go with a larger Honda unit, so even though you're running a bare bones system you'd do well to swap out the stocker for a larger alternative with more cooling capacity.

Beyond that it could be that there is a wiring snafu you've missed, but even if it is all "correct" it is possible that the stock R/R was on its way out before you ever started down the path. Swap it out for another R/R and see if the problem persists.

Good Luck, and welcome to the forum!

Regards,

[posplayr]

I'm on a blackberry so can't find it but if u do a search for. "550 bobber schematic" I did a minimalist schematic.

[overheat]

I'm on a blackberry so can't find it but if u do a search for. "550 bobber schematic" I did a minimalist schematic.

I took a look at it but I still am not sure what is wrong. Thanks.

[Planecrazy]

Once again ... don't overlook the possibility that the R/R was failing before you ever connected it. You may have done everything right...

Regards,

[overheat]

I guess I'll have to see if I can get my hands on a new(er) r/r.

[Suzuki_Don]

I guess I'll have to see if I can get my hands on a new(er) r/r.

Not new -- but 2nd hand Honda.

[hikermikem]

I guess I'll have to see if I can get my hands on a new(er) r/r.

One of the members here sells Honda R/R's that he modifies and are plug & play. I've used a couple with good results...

PM him, "duaneage"

[duaneage]

I bet one or more diodes inside the RR are shorted out. that heats the RR right up. Next to go will be your stator. I can hook you up with a new Honda RR kit for 45 dollars delivered. And I can ship tomorrow.

[cowboyup3371]

I bet one or more diodes inside the RR are shorted out. that heats the RR right up. Next to go will be your stator. I can hook you up with a new Honda RR kit for 45 dollars delivered. And I can ship tomorrow.

And it gets there before you know it. Trust me, I know!

Thanks Duaneage.