charging problems

**C.V.** · 06-19-2008, 09:07 AM

I recently istalled the electrex RR, and it works fantastic, and its easy to install, except I needed to buy some longer bolts to mount it, as the mounting ears were much thicker. HOWEVER, I wouldn't just buy a RR and hope that it cures the problem without fully troubleshooting first. There are a dozen other things that don't cost a fortune that could be causing the problem (double check those connections, seriously!) so it makes sense and is fairly easy to isolate the problem. There is an excellent step by step flow chart in the garage section here, it got me through my charging problems (bad connections and a failed R/R) with ease. Good luck!

**doctorgonzo** · 06-19-2008, 09:08 AM

Originally posted by Nooner

I'm new to the sport. Like many, gasoline $$ started me shopping. Purchased a 1981 GS550T. In good shape (4,000 miles) but had a battery issue (since replaced). Now it appears that I have a charging issue.
I had the bike gone over by a competent mechanic and I am sure that all grounds and connections are OK. I have read the stator papers on this site and am giving serious consideration to the replacement parts from ElectroSport.

I'm more cocky than good at mechanics.

My questions:
1. Has anyone tried the ElectroSport Regulator/Rectifier and Stator replacements?
2. In your opinion do they solve the charging problem?
3. Can you give me some idea on how difficult they are to install? ( Skill wise, I do routine maintenance and tinker with an old tractor, no real experience on the electrical stuff)
Any insight you might have is much appreciated. My current thinking is to spend the money on these parts and do away with the problem, but money is an issue and I wonder about the wisdom of doing it myself. Opinions? Thanks.

1. I have both from electrosport, no problems. My electrosport stator puts out lower voltage than OEM (may just be the particular one I got sent), but enough for good charging. They are less expensive than OEM, and most people get good results from them.
2. They do IF, you do all the other suggested things like cleaning up wiring, ground straight to battery, etc... otherwise you'll just wind up trashing the new ones as well.
3. A 10 year old could do the R/R unit. The stator is a bit of a pain, but certainly not beyond even the reasonably handy person.

That being said, I'd do the tests in the Stator Papers. R/R units are hard to test. I've had one test good and still be the source of the problem, but test the Stator for sure and don't replace if not needed.

**Dave8338** · 06-19-2008, 09:11 AM

Buy a good volt meter/ tester and dig in. The Honda R/R conversion is easy and a lot less expensive than the ElectroSport set up. With 4K on the clock...I'll bet a small pile of money that it is not the stator. Unless you yourself have gone over ALL of the connections (cleaned and greased) and spent some time checking the voltage at various points in the harness...there is no way of telling wether or not, things are in order.

When it comes to these bikes, the R/R (if the voltage is above the 15.5 range at 5K RPM's) is usually at fault. But dont rush out and throw money at it, until you done the homework. My .02.....

Welcome to the GSR. There is NO shop on the planet that has the knowledge of these bikes, to the extent you'll find right here!

**jbs80106** · 06-19-2008, 09:23 AM

Welcome to the Club!!!

I've done the reg/rect/stator from electrosport on my 650. If they are singularly or together the source of your charging problem they'll solve it nicely.

On my 650, reg/rect is a single unit mounted underneath the bike. Remove a few bolts holding the mounting plate in place and you can get it off/on to do the swap. Note that on some bikes (maybe your 450?) the regulator and rectifier are 2 different components....I am not certain about yours.

While on the reg/rect, there is a member here duanege, who sells an alternate solution using a more modern and reportedly more robust honda modification. If mine fails again, I'm going that route. Also, some suggest fabricating a new mounting location to help keep the unit cooler. With limited fabrication experience or skill, I just put mine back into the stock location.....

Stator....again, not too hard to replace. Check out Basscliff's website for some pics to step you thru. A few suggestions:
- make a cardboard trace of the stator cover and poke some holes to help you keep track of where the screws go...they're not all the same length
- buy a new stator cover gasket from your local dealer for about $13.00 and get some oil because you'll lose a little when you pull the cover off.
- pulling the cover off can be a challenge. I worked around mine with a rubber mallet several times to help break the old gasket free. There's a magnet in there that hold pretty strongly to the cover...but not ridiculously so. If it won't budge its the old gasket holding it on.
- On mine it took some help from my neighbor to get some of the screws free that hold the stator inside the cover. I held it tight, he worked the screw driver. One of my phillip's heads stripped and we replaced it with an appropriate stainless hex head for the next time....

I'd HAPPILY trade doing stators/reg-rects for ANYTHING involving removing the carbs...my current PITA! getting them fully reseated is still a challenge.

Good luck!

**doctorgonzo** · 06-19-2008, 09:30 AM

"I'd HAPPILY trade doing stators/reg-rects for ANYTHING involving removing the carbs...my current PITA! getting them fully reseated is still a challenge."

For me that's the Ying and Yang of pods. Have caused me to have to pull my carbs multiple times as I try and get it dialed in even with a kit from dynojet, BUT at least now they come off and go on in about 5 minutes each way.

**Nooner** · 06-20-2008, 12:29 PM

Thanks for the advise, I'll give the connections a good look this weekend.

**spyug** · 06-20-2008, 12:50 PM

As has been previously stated, don't go throwing money at it unless you've done all the testing. All the information is there to determine what is going on.

Again, as stated, many of the charging issues encountered with these and other Japanese bikes of the same era can be blemed on bad/ineffective grounds and corroded connectors.

Before doing any tests, locate and clean all connectors. Clean and tighten grounds and run a seperate ground lead from your rectifier ground (black white wire) directly to the negative pole on the battery.

These little chores alone may sort you out but if not then we need to follow the fault finding flow chart and find out what else is causing problems.

Be methodical and approach it in steps. The urge to get riding often over rides common sense and the first instinct is to replace everything so we can get scooting. Don't be sucked in. Be patient and as they said in "Apollo 13" "work the problem".

Good luck with it, read the threads and ask the questions.

Cheers,
Spyug.

**duaneage** · 06-20-2008, 06:12 PM

I offer Honda RRs in a kit to replace the Suzuki OEM units. They are quite popular and for 40.00 delivered reasonably priced. PM me if interested.

**BassCliff** · 06-20-2008, 06:31 PM

Cooking with electrons

Hi Mr. Nooner,

Solving charging problems is accomplished by proper maintenance, troubleshooting, and lastly, replacement of faulty parts. The Stator Papers (a most excellent document linked to in your mega-welcome) and my website (also linked to in your mega-welcome, and in my signature file) have quite a bit of troubleshooting and replacement information for your perusal. I've always used Mr. duaneage's Honda r/r replacements. I've used RMStator and Electrosport stator parts and all work well when properly maintained. Good luck. Keep us informed.

Thank you for your indulgence,

BassCliff

charging problems

charging problems

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