1983 GS850GL - Blowing Headlights, idles at 18 volts

[TastyChevelle]

Hi GsResources,

I am new to electrical systems and am trying to wrap my head around the common electrical issues I've read on this site. I have mostly seen charging issues where the battery dies, which points to the stator phases going out, but not quite sure about over charging.

I've blown 2 headlights now and finally measured the voltage on the battery as it is running. 18 volts idling at ~1000 rpm, 19.5-19.9 volts slightly revving, maybe ~2500-3000 rpm.

Is this an easy fix or do you knowledgeable folks need more information?

[Brendan W]

The regulating part of your regulator/rectifier system is not working to keep the voltage controlled to about 14.4 Volts.
Symptoms include blowing bulbs and if not fixed for a while, boiling of battery. Check what the electrolyte level is.
Many of us have replaced the R/R with an SH775 series unit.

[TastyChevelle]

The regulating part of your regulator/rectifier system is not working to keep the voltage controlled to about 14.4 Volts.
Symptoms include blowing bulbs and if not fixed for a while, boiling of battery. Check what the electrolyte level is.
Many of us have replaced the R/R with an SH775 series unit.

Great! Sounds like a simple replacement. Is the SH775 preferable to a Suzuki OEM unit?

And I have an AGM battery in it. Is there anything I could check on that?

[Rich82GS750TZ]

Yes. Do some searching on the site. Use advanced search, put in your keywords. Choose titles only to get any meaningful search results.

welcome to the site. Some useful links for you in my signature. The charging system sorted thread had my complete charging system saga, but there are many just like it on the forum. Basically, a new (used) genuine Shindengen SH 775, probably a new stator, clean up your wiring, eliminate the headlamp loop, should get you going. If I were you I’d start with a new good battery. I wouldn’t trust the one you have.

[Brendan W]

Great! Sounds like a simple replacement. Is the SH775 preferable to a Suzuki OEM unit?

And I have an AGM battery in it. Is there anything I could check on that?

Don't know if the oem is even available and even if it was I would not get one. It was designed to allow the generator to run at full whack and dump the excess into the generator windings. When regulators failed this had the added bonus of frying the stator windings. The SH775 unit switches off the current if not needed and I've only seen one report of a failure.
Some of the guys here have listed sources for one but beware of pretend copies or same as deals on ebay. Again, lots of threads here about that issue, how to recognise a genuine part and how to wire them up including the elimination of a loop to the headlight that won't be needed.
Know nothing about AGM except how to spell it. For the time being avoid riding it.

[TastyChevelle]

Don't know if the oem is even available and even if it was I would not get one. It was designed to allow the generator to run at full whack and dump the excess into the generator windings. When regulators failed this had the added bonus of frying the stator windings. The SH775 unit switches off the current if not needed and I've only seen one report of a failure.
Some of the guys here have listed sources for one but beware of pretend copies or same as deals on ebay. Again, lots of threads here about that issue, how to recognise a genuine part and how to wire them up including the elimination of a loop to the headlight that won't be needed.
Know nothing about AGM except how to spell it. For the time being avoid riding it.

Thanks! I'm reading up on regulators. Is what you're describing with the current dump into the stator windings a shunt type regulator?

And looks like genuine SH775's on Polaris parts sites (p/n 4012941) run ~$200

But just bought a used one on Ebay for ~$60

Thanks guys! Learning lots!

[Rich82GS750TZ]

You don’t need to buy a new SH775. Look up member Nessism and see if he has a used one that’s tested. Or find one on eBay. If you find one on eBay and you’re not sure if it’s genuine, post it here and we’ll try to help you out.

Oh, I see you found one. Might we have a look?

[TastyChevelle]

You don’t need to buy a new SH775. Look up member Nessism and see if he has a used one that’s tested. Or find one on eBay. If you find one on eBay and you’re not sure if it’s genuine, post it here and we’ll try to help you out.

Oh, I see you found one. Might we have a look?

Sure!

https://www.ebay.com/itm/Polaris-Ranger-RZR-1000-800-570-Turbo-ACE-150-Voltage-Regulator-4012941/303341885592?epid=6011079939&_trkparms=ispr%3D1&hash=item46a095d898:g:B-0AAOSwY2tfr60g&amdata=enc%3AAQAFAAACcBaobrjLl8XobRIiIML1V4Imu%252Fn%252BzU5L90Z278x5ickkpFtSR0CGv%252Bh98r8Yb9quS9EBdTF7z%252FfDHbLPwMR88u8UPb3D4ifqObAKEXZV9xoOvw8pu5wCV03XsBIV6IPcsSVAMZQ0bUwKH1LIPxubrijpulYpz%252B1vOwBYMedPTDCEqX9CeMLnHOUbupjj8YwCcC81usnEjp5hZaNorguGJTxzHYjfrA%252Fr%252BJaHbPjEb406gkABqRvbz%252FWadZtOqohgmytWURBsQYh98nkMTakjYbwlI%252FKnlBPLSAJErsDaLZgd%252BDXodITucPdURsA8flsgip9JDg0RA0zkEizB96fSTQ0tP8kd7l2PKUfDjfHqJfbmWubM4IEsYT7J%252B1Cwev%252FGHQfzf7UVTp0uLRK3lghaCbTnjoq9qZSDABFpTVStT963V4iBMS1VXRXsz%252FrFRkfq0IfIGID6xEThznetnwtzhe2n8v2YJuDQhjTPgpFgb1e0VTvU3cs3KtKr5LoGXws5AC6tTbJCMwVjfX3xF%252FCOWTJJNgs4sB0Kg%252B4C%252FkSh1j%252FJcO60ykRqgitO%252FEutdpxOLJs%252FUpEvZBsxf%252BFR99Q5bgAJpoTQlKtMA9FKQUkK5Zr3rhhC4nTkiktB%252F1g1k%252F%252FrVY774sB9u7%252BwA9nA4oyMTAl%252FHNyMsML8uoKQeLOdCIh0h1GDMgkkDO%252FzOGVNh1l90ZdSmxkB2G3ETVBwzD83USM3NLxyCJQR%252F5KtF2qfWJ8XShm2MJczG4dk%252B2l8BflGbpN6Z4nb%252FbbsUZH1I0yfCFCsmF3woYj7otKqubupW4%252BFQUg8wnX1wNmY%252BemJT%252FPitg%253D%253D%7Ccksum%3A303341885592ae2d7282c5ea4bde9304d7b351d55a6d%7Campid%3APL_CLK%7Cclp%3A2334524

[Nessism]

Sure!

https://www.ebay.com/itm/Polaris-Ranger-RZR-1000-800-570-Turbo-ACE-150-Voltage-Regulator-4012941/303341885592

Looks fine. Triumph has a pigtail harness that plugs right in that sells for about $10.

Wire it up like this...

SH775 Install by nessism, on Flickr

[Grimly]

Sure!

https://www.ebay.com/itm/Polaris-Ran...Cclp%3A2334524

Yep, powersportsnation is a trusted seller of genuine good used ones, in my experience.
Caution - don't start the bike until you fix this, else you'll kill your ignitor.
18V hasn't done it any favours already, so just hope it's not damaged.

[Redman]

If you are on your way of replacing with a sh755, do proceed with that.

whats the chance the 850 has had a Honda r/r installed? Can tell because it will have the 3 stator wires, the positive and the ground like stock and most, but the Honda will also have a “sense” wire that others don’t, and needs to be tied to a positive that is switched off with the key (often power to brake lever switch). Reason I ask, is if you do have one of those Honda r/r (a common improvement for some time) and If that Sense wire is disconnected or other such problem with it that r/r putts out max it can all the time. I had this happen, 17v at low speed and over 19 at speed. Just thought I would mention it.

[TastyChevelle]

If you are on your way of replacing with a sh755, do proceed with that.

whats the chance the 850 has had a Honda r/r installed? Can tell because it will have the 3 stator wires, the positive and the ground like stock and most, but the Honda will also have a “sense” wire that others don’t, and needs to be tied to a positive that is switched off with the key (often power to brake lever switch). Reason I ask, is if you do have one of those Honda r/r (a common improvement for some time) and If that Sense wire is disconnected or other such problem with it that r/r putts out max it can all the time. I had this happen, 17v at low speed and over 19 at speed. Just thought I would mention it.

Hi,

I don't think it had a Honda installed, here are some pictures (sorry, wasn't able to upload them but hopefully the link works):

https://i.imgur.com/DfBnoMw.jpg

Can't quite make out the writing:

https://i.imgur.com/Jrp6vS5.jpg

However, I do have this reg/rec from my old 1982 Kawasaki KZ that is out of commission I could steal for the time being:

https://i.imgur.com/y7IMPDe.jpg

Shindengen SH230:

https://i.imgur.com/OE1sH0z.jpg

6 wires:

https://i.imgur.com/eN474nb.jpg

https://i.imgur.com/4pahnDF.jpg

Any idea how this SH230 would wire up to my bike?

[TastyChevelle]

Yep, powersportsnation is a trusted seller of genuine good used ones, in my experience.
Caution - don't start the bike until you fix this, else you'll kill your ignitor.
18V hasn't done it any favours already, so just hope it's not damaged.

Hi,

I've probably put a good amount of miles on the bike the way it is. Any suggestions on how to check the health of the igniter?

[TastyChevelle]

Looks fine. Triumph has a pigtail harness that plugs right in that sells for about $10.

Wire it up like this...

SH775 Install by nessism, on Flickr

Hi Ed,

Thanks, looks simple enough! I ordered this kit earlier today:

https://www.amazon.com/gp/product/B00UI4L0IE/ref=ppx_od_dt_b_asin_title_s00?ie=UTF8&psc=1

[Rich82GS750TZ]

I initially bought that same Amazon connection kit to connect my SH775. It worked fine, but, a few months ago I replaced it with the legit item from Triumph for the same money. The Triumph kit is WAY better. Connections are potted into the terminal blocks, and the wires are a much thicker gauge.

regarding posting pics: you already have an Imgur account, that’s half the battle. The rest is a little tricky, but once you know how will be no big deal. Follow the link in my signature.