Maybe its a short?

[Killer2600]

I watched a RR blow the main fuse on a GS550T as soon as the engine started. I replaced the RR and it never had the problem again.
Your free to try this as a solution, or examine it as much as you want.

While I question your theory, posplayr will never be wrong - at least in no way he/she will admit to. I've never seen or met posplayr but I'm reasonably certain posplayr is a woman.

[posplayr]

Nothing is ever perfect enough for you and you over analyze words until you lose sight of the meaning for them.

Do this, take a look at your little R/R schematic. See the cathode on the SCR, see where the trace goes to a frame ground symbol, see the battery negative, see where it also goes to a frame ground. Shunting or shorting to ground seems an accurate enough description in my book and would apply to separate rectifier/regulator circuit where as yours is limited to a single design.

You don't seem to understand the description in the manual, the schematic, or my explanation. The R/R will shunt the stator even if it is disconnected from ground!!! So when you describe a shunt to ground meaning a shunt to frame ground how is that possible if the R/R is not even connected to the ground. So how does that work??? The plain answer is that it is not possible because your description is not only misleading but it is flawed. For someone supposedly trained in electronics it I would think that you would have some obversion to propagating falsehoods; apparently I'm giving you too much credit

[posplayr]

I watched a RR blow the main fuse on a GS550T as soon as the engine started. I replaced the RR and it never had the problem again.
Your free to try this as a solution, or examine it as much as you want.

I'm not doubting it is the R/R that needs to be replaced, just trying to relate the symptoms to the failure modes.

If the R/R(+) to R/R(-) was shorted then the fuse would blow anytime the battery was connected. Apparently not the case here.

If the fuse fuse blows on startup, then it is probably a FAILED OPEN SHUNTING SCR (1 of 10 times)allowing unregulated DC to surge at startup into the battery and blow the 15 amp fuse.

A FAILED SHORT SHUNTING SCR is most common (9 of 10 times) and would probably just smoke the R/R and the stator as there will be an unrelenting short on the stator winding.

[posplayr]

While I question your theory, posplayr will never be wrong - at least in no way he/she will admit to. I've never seen or met posplayr but I'm reasonably certain posplayr is a woman.

It only seems like I'm perfect when compared to your sloppy posts and analysis.

[Killer2600]

You don't seem to understand the description in the manual, the schematic, or my explanation. The R/R will shunt the stator even if it is disconnected from ground!!! So when you describe a shunt to ground meaning a shunt to frame ground how is that possible if the R/R is not even connected to the ground. So how does that work??? The plain answer is that it is not possible because your description is not only misleading but it is flawed. For someone supposedly trained in electronics it I would think that you would have some obversion to propagating falsehoods; apparently I'm giving you too much credit

It only seems like I'm perfect when compared to your sloppy posts and analysis.

Your nothing if not predictable. It's easy to get a rise out of you.

I had a boss like you, very technical, knew it all type, who had to teach you HIS way because you were an idiot else-wise. As smart and indispensable as he thought he was, no one liked him - not an employee, customer, or business partner. No one ever cared to ask for his input or presence and often worked for the opposite goal.

My posts and analysis may seem sloppy but my target audience understands them and that's all I care about. Those that can decipher your technical writing and actually understand it probably fixed their electrical without needing to come on the forums.

[posplayr]

Your nothing if not predictable. It's easy to get a rise out of you.

I had a boss like you, very technical, knew it all type, who had to teach you HIS way because you were an idiot else-wise. As smart and indispensable as he thought he was, no one liked him - not an employee, customer, or business partner. No one ever cared to ask for his input or presence and often worked for the opposite goal.

My posts and analysis may seem sloppy but my target audience understands them and that's all I care about. Those that can decipher your technical writing and actually understand it probably fixed their electrical without needing to come on the forums.

You must have missed this poll. 80% polled got the answer correct. So I don't think your comment about me over complicating this is valid.

http://www.thegsresources.com/_forum/showthread.php?t=157589

On one of the rare occasions that Bakalorz seemed to be agreeing with me. He referred to my figure below. Even though he was technically correct, his explanation did in fact over complicate the explanation necessary for understanding the basic ground ing theory. I seldom mention what Bakalorz points out even though I agree completely with what he pointed out here.

http://www.thegsresources.com/_forum/showpost.php?p=1195383&postcount=58

Here was at least one very appreciative reader. Please note his very astute remark about what the point of the contest , Single point grounds and the GS Charging system Health.

Originally Posted by Mad GS 750 E
I think its #5 ,all the currents return to R/R ,and is burned off as heat.Thats why in your GS system health tread you tell us to do the single point ground as close to the R/R as possible,from the harness,frame, and battery.Posplayr your thread on the electrical system really helped me out,you are the man. (I do get extra points for A$$ kissing right) LOL!

http://www.thegsresources.com/_forum/showpost.php?p=1195059&postcount=52

Providing simplified explanations is the ultimate goal because everybody knows you can always make it more complicated than necessary. However having a simplified explanation that doesn't provide the tools to understand , doesn't match the observations and/or would lead to performing improper "fixes" is a bad explanation (in my opinion). I would even call such an explanation (given the context) as being WRONG.


In the current context for understanding:

• how the charging system actually works and
• how the grounding should be configured to improve charging ,

It doesn't seem overly complicated to me to simply explain and point out what is already in the Suzuki shop manual.
For myself, I was certainly motivated to figure out what the heck was going on on my 1980 GS750E when I first got it. This bike was in essentially stock condition with no modifications. I found it with burnt ground wires between the two harness ground lugs (frame and solenoid/side plate). If you look closely all of the insulation was burnt off of those two wires. The current was all ground current outside of the harness, as the harness had not been damage. You explanation of sinking all currents to ground provides no guidance as to what possibly could be going on here as both ends of the wire are already connected to grounds. So most of the theory and explanations that I have presented here are in fact simplifications of both the electrical theory and the Suzuki electrical designs but with sufficient richness (i.e. complexity) to explain why the wires in the picture burned up.

I should point out that although that harness was burned and the battery was over charging and boiled out, by making the corrective recommendations (as outlined in GS Charging Health ) for a cleaning contacts, single point ground , cleaning the fuse box etc.... the bike charging was restored to near perfection (given the stock parts) and there was no need to replace either the stator or the R/R. In other words the only problems was in connections and grounds.



So Killer please keep in mind, you are NOT getting my goat or riling me up. I could really care less what you think or what you do. However when you come here to the GS resources and make what amounts to erroneous statements and further statements which tend to push back the known body of knowledge, there is a responsibility for members here to correct such information.

You have taken this personally and have taken to escalating personal attacks against me which are inappropriate. If it was not for how immature so many of these personal attacks are (calling me a girl?????) I might have a tendency to respond with much more vigor (however see comment above about I could care less about you). Instead, I have just posted the information above to make it more clear to any readers what the relevance of my statements are in the current context. The descriptions are intended to provide explanations for the many observations of charging system malfunction and provide a theoretical explanation for the specific recommendations I have made in GS Charging System Health.

Posplayr

P.S. As people get older they have a tendency to keep the mouth running and the ears closed; this doesn't really give the mind enough time to think. Better to keep the ears open and mouth shut and let the brain catchup with the discussion.

P.S.2 I also have realized that the stator pages that are being maintained by this site are a not too veiled marketing tool for Electro sport. The new reader is left with the impression that they should go out and by Electro sport products to solve their GS charging system problems. I have sent emails to the author and have about the new information posted on this website and have had no feedback related to the GS Charging System health posts nor any acknowledgment that that beyond the grounding and wiring solutions, there are two excellent options for R/R's specifically.

The Honda (or equivalent 6 wire R/R formerly sold by Duanage)

http://www.thegsresources.com/_forum/showthread.php?t=167974

The SERIES R/R's (Compufire or CycleElectric)

http://www.thegsresources.com/_forum/showthread.php?t=167939

None of the Electrosport products other than having 3 SCR legs (good to do but certainly not the best) has done anything to improve this situation:

http://www.thegsresources.com/_forum/showthread.php?t=167978

There are even MOSFET R/R's commonly available which are better than the Electrosport SCR shunt R/R. See these listed in Matchless's thread on R/R par numbers.

In fact the only thing the Electro sport R/R is better than is the old single phase regulated shunt R/R's like the one I had in my 1981 GS750E.