78 GS1000 Recifier hot wires smoking?

[Tonyp884]

I am trying to restore a 78 GS1000. The charging system is not charging. I have ordered a regulator and stator. I started the bike today after running about 15 seconds the rectifier got very hot, I could tell because the wires connected to it were smoking.
I disconnected the battery.
Now, I need some help!
Can you guys give me some insight?
thanks,
Tony P
Monroe, NC

[Tonyp884]

I am getting confused. I have read the the regulator and the rectifier are the same. But I have on my 78 GS1000E a regulator and below it to the right is what I am calling the rectifier.
As you guys can tell, electrical is not my thing. I hate to scrap this bike, but I hope I am not in over my head.
I should receive a New Stator and a New R/R ( Regulator / Rectifier?)in the mail any day now.
On page 182 of the GS1000 manual from Clif Storage it shows the electrical stuff behind the left side cover. And that drawing shows a regulator, rectifier, turn signal, fuse box, and starter relay.

I appreciate any help, I'd love to get this GS1000 on the road again!
Thanks,
Tony P

[celesboy1]

its must be short cables then....

well...actually charging problem is not that hard for me....(i'm pretty sure if GS250 and GS1000 have almost same schemes electricity)

what u should do next is....dont use those original charging wire...you can made some DIY wiring like me....

i assume your stator is have 3 output wire (3phase stator) just like my GS250
so..just extend those 3 output from stator directly to R/R with your DIY wire (i'm use 4mm copper cheap chinese made wire) <--- i'm not use genuine wiring set anymore...its sucks

ok...first thing finish....next thing is to connect R/R to battery

you can connect R/R to battery using same method like you use to connect between stator and R/R

but you must carefull this time....because battery have polar + and - (dont make mistake or your CDI , etc will burnt instantly)

i can post diagram if u want.....sorry for my bad english

[rustybronco]

I am getting confused. I have read the the regulator and the rectifier are the same. But I have on my 78 GS1000E a regulator and below it to the right is what I am calling the rectifier.
As you guys can tell, electrical is not my thing. I hate to scrap this bike, but I hope I am not in over my head.

The '78's used separate regulator and rectifier's. You can replace them both with a combined unit.

[celesboy1]

The '78's used separate regulator and rectifier's. You can replace them both with a combined unit.

soo true....just buy a R/R (combined) just like in newer bike....more reliable and easy to snap it

[Tonyp884]

Celesboy, yes a diagram would be great!
So, you guys are saying that my bike DOES have a Rectifier AND a Regulator. And I ordered a new stator and a R/R which apparently IS a Rectifier And Receiver all in one unit. I just need to understand how to wire them.
So, When I started the bike and the rectifier wires started smoking, does that mean that my stator IS Charging?
thanks,
Tony P

[rustybronco]

So, you guys are saying that my bike DOES have a Rectifier AND a Regulator.

And I ordered a new stator and a R/R which apparently IS a Rectifier And Receiver all in one unit. I just need to understand how to wire them.


So, When I started the bike and the rectifier wires started smoking, does that mean that my stator IS Charging?
thanks,
Tony P

Yes

How to wire it is on bikecliffs website. http://members.dslextreme.com/users/bikecliff/

It means your connections suk.

[Nessism]

When you get your new stator and R/R, rewire the charging system to send the stator wires directly into the R/R, NOT into the factory harness. Suzuki's charging system routing sends one stator leg up to the headlamp switch which causes nothing but troubles as the harness ages and resistance builds in the circuit.

Ground your new R/R to a solid frame point, or to the negative terminal of the battery.

You can feed the + output from the R/R directly to the battery (add a fuse in-line if you choose this option), or into the fuse box. If you choose to go though the fuse box, make sure the circuit connectors are clean and free of corrosion. Use Posplyer's procedure to measure voltage drop. DO NOT SKIP THIS STEP. Check this link for info on what to do. http://members.dslextreme.com/users/...dd-n-ends.html

We get countless newbies around here that short cut bike maintenance tasks then get frustrated when their bike proves unreliable. Consider this your warning.

[uk gs nut]

reg/rec

All good info, but dont worry about the two wires you have left over. Thats the light switch loop, tape them up and forget them good earths are important !. You could check your output from the stator with a volt meter with the engine running, 60V per phase at 5000 rpm may save you time and cost of a stator. Good luck.

[rustybronco]

All good info, but dont worry about the two wires you have left over. Thats the light switch loop, tape them up and forget them good earths are important !. You could check your output from the stator with a volt meter with the engine running, 60V per phase at 5000 rpm may save you time and cost of a stator. Good luck.

I should receive a New Stator and a New R/R ( Regulator / Rectifier?)in the mail any day now.

Too late as he's already bought a new one.

[uk gs nut]

He could return for a refund , a few extra beer tokens maybe.

[celesboy1]

Celesboy, yes a diagram would be great!
So, you guys are saying that my bike DOES have a Rectifier AND a Regulator. And I ordered a new stator and a R/R which apparently IS a Rectifier And Receiver all in one unit. I just need to understand how to wire them.
So, When I started the bike and the rectifier wires started smoking, does that mean that my stator IS Charging?
thanks,
Tony P

its wiring diagram below.....but if you need to know where the input and output in your new R/R....then you should post here what tipe R/R did you buy....as far as i know....there's 2 kind of connector in R/R....(with several cables outside the R/R.....and just a socket without cables at all)
i assume your new R/R are shindengen brand yes ?



forget about ignition switch in diagram above if you want make DIY cables....
just focus to wire between stator and R/R....then between R/R and battery <----thats the main point (i was do DIY cables in my bike too few years ago....and works fine till now)

[Tonyp884]

UK GS Nut:
What do you mean do not worry about the two wires left over?
And I do not understand 60 volts per phase!
I am not an electrician. Can you explain?
thanks,
tony p

[celesboy1]

UK GS Nut:
What do you mean do not worry about the two wires left over?
And I do not understand 60 volts per phase!
I am not an electrician. Can you explain?
thanks,
tony p

ok tony....please be patient....we re here to help you with all might...just calm....hehehe

dont bother about wires left over and 60volts....we can disscuss it later....after you finish do DIY wires (stator---R/R---battery)


i want to ask first...can you post pics of your new R/R socket ? this will make your homework much more easy i think
coz with that pict....i can explain to you easily wheres input from stator to R/R , and wheres output from R/R to battery

i'm not electrician too....i'm just poultry marketing for years....but i'm learn charging schemes in my bike just in 2 weeks by myself....and its not that hard once you already understand the main points

[Nessism]

The business about the stator output is outlined in the Stator Papers. Please read this document, all of it, including Pos's update.