battery issue 1983 gs 650 gl

[tkent02]

No, go through all of the testing, find out where the problem lies. Have you cleaned every connector in the entire charging system yet?

[tom203]

What brand of R/R is it ? any markings ? how many wires -5, 6 ??? wire colors?

[lrgguy]

Tom theres 5 wires .. im back at work so cant tell you the colours ... no I didnt see any markings on the rectifier ... but did call the to cycle salvage and they dont have an original suzuki rectifier but they do have an aftermarket one he sais new . That basikly is exact same as the one on my bike .. plug it right in and hook up the ground ...but for the low low price of $250 bucks
They tell me I cant just put any rectifier in cuzz pins may be set up differant ... again electrical crap isnt my area of experience !!

[tom203]

"......but for the low low price of $250 bucks "

deals like that are no brainers- ask them if it comes with entire bike!

You need to do posplayr's tests to check entire system.
You'll probably want a SH-775 - this is a series R/R- ATV polaris part
Polaris p/n 4012941; In states these go for about $75 shipped. Honestly this is best way to go (assuming you want to keep this bike)

Ignore any and all nonsense about monster mosfet R/R 's- these bikes have a small charging system and the SH-775 is ideal.

[lrgguy]

Ok so I removed the seat and exposed the white and blue , white and green , and yellow wires and performed the NO LOAD test .. all appears to be good using tester took reading between blue white and yellow white blue and white green and white green and yellow .. while high beam was on and rpms up at 5000 .
All 3 readings were up around 86 volts of ac to 92 volts ... however when firat looking and before disconnecting wires , noticed the blue whit was mealted to the yellow and had a fair bit of corrossion ... I cleaned all connections and attached wires . Then ran bike again noticing the blue white whire gets VERY HOT !!! would this be due to the R/R not regulating amps ??

[lrgguy]

OK HERE WE GO !! DING DING DING ... WE HAVE A WINNER !!

where the rectifier conects (plugs in )via some white plug connector beside the battery box .. it is just a big melted mess !! Grrrr so yeah its a givin the rectifier is pooched !!!

[lrgguy]

Connector fried !! Should I assume the rectifier is pooched ? Or clean all contacts and hook back up ?
Its odvious something got very hot and mealted this ... would that be the pooched rectifier ?

[tom203]

Yeah, you got some work to do- good news is that you don't want/need that connector. You want the 3 stator outputs direct to a good R/R skipping any connector plug.

you said "....All 3 readings were up around 86 volts of ac to 92 volts " - this was doing the AC test with stator disconnected from R/R ,right???? If so, this means your stator is likely still good despite being tortured by the crappy R/R.

You need to read some of posplayr's clues to charging health. I'd strongly opt for the SH-775 and fix/clean all connections.

[lrgguy]

Well I do know this rectifier isnt an original !! So I think ill do the same and not buy the original $250 doller one and ill put in whatever I can get my hands on tonght ... plan on selling this bike when I get the new one hopefully in the next week ... there is 3 yellow wires 1 red and 1 green coming out of this rectifier .. no name or description on it other then someone carving in the numbers 30302 16 in the side of it with a screw driver or something ... grrrrr its 19 degrees here and I wanna ride !!!

[tom203]

"grrrrr its 19 degrees here and I wanna ride "

65 here, snow vanishing as you look at it. My bike will escape its prison next week -with new rear tire!

[lrgguy]

Ok picked up a new R/R wired up exactly as before .. all new connectors saudered all connections . Started it up !! First thing I noticed was the rpms wereway low the bike would barely run ... adjusted idlle to make it run without me holding throttle ... 2 nd notice when I try to rev bike , it just doesnt sound proper !!
3 rd I notice the blue and white wire is hot again !!
Im thinking this blue and white wire was the culprit that mealted everything to begin with ...
Confused !! Frustrated !!
I have dropped $1200 bucks in new parts in to this bike in the last month now and oly paid $1000 for the bike one yr ago ...
New battery
New rectifier
New spark plugs and new caps
New fork seals
New front and rear tire
New rear indicator lights
4 new carb boots motor side
New valve gasket
Oil changes filter
Changed shaft drive oil
New handle grips
And im sure im missing afew things I have done
Oh new front and rear breaks
Ready to pour gas over this bike and light it !!!

[lrgguy]

When I put multimeter on pos and ground on battery now it reads 14.2 now !! With old R/R it was at 16.2 , so it appears as though the battery is charging now ..but why would this blue and whit wire be scorching hot ??

[lrgguy]

followed the blue and white wire down behind battery box , and found a bogus connection !! Someone had joined the blue and white wires with a piece of electrical tape and it was all corroded !! Cut out section and unfortunately had to use attach wires with male and female connects for the time being , now the blue and white wire doesnt seem to be heating up ..
Fingers crossed !!!

[lrgguy]

Well all appears to be working !! Fingers crossed ...
Going for a ride around the neiberhood staying close to home to see how she runs ... thx to all who offered suggestions and helped me getting this issue resolved !!!! Greatly appreciated for you all taking your time to assist me ..
Counting down the hrs till tomortow morning , going to look at this 78 suzuki gs 1000 E and hopefully bringing it home ...

[lrgguy]

Ok bad news !! Made it to the end of the driveway !! Only two plugs are firing now !! All four plugs were firing pryor .... only thing changed was a rectifier removed and new rectifier installed .. old rectifier had 3 yellow wires 1 green 1 red ... newrectifier had 3 yellow 1 red and 1 black wires and paper that comes with rectifier says black Iis ground ... why would only 2 cylenders be firing now ???