1983 GSX250S Build

[Woodsy]

Hmm okay did some tests today, pulled the kill switch and ignition apart and cleaned it up, no difference, and its getting the same voltage that the battery is putting out, however.... when i test the regulator resistance with the multimeter and the 'ohms', i get nothing on all counts, when i should be getting some resistance according to my manual, so i'm hoping this is the problem, but i doubt it.

[pete]

I think modern multimeters do diode tests differently to what's in the manuals.

They indicate they should show 1.5v or something weird like that, whereas modern multimeters just show open circuits, so I don't know that those tests are relevant...

Of course it could be that I've had too much red wine...

[Woodsy]

Wine?.... dude your man level just dropped dramatically lol

I dunno what else to do, its got 9volts, i flick the kill switch and it drops to 5v and hitting the starter drops me to 4v, would that say that there is something wrong with the kill switch wiring harness? dropping it so many volts?

[pete]

Man level? Hahahahahahaha

Red wine's good dude... at least good red wine is good... meh... scotch is good too... as is beer... but I can't do rum any more...

As to the voltage, definitely something not right there.

Double checked your grounds? What does it read at 5k RPM or so? Is your electrics tray earthing properly to the frame and/or battery negative?

[Woodsy]

I pulled the battery and leads out today and they are perfect, checked them for resistance etc too.

Grounds are clean and solid, getting the same amount of power on both sides of the fuse. I dont think its the stator because the bike was starting fine before i pulled the engine out, i do have a spare earth on the rh side of the bike but i have always had that not sure what its to though.

[pete]

Hmmm... a little too fuzzy to think more at the moment, see if I can think of something in the morning...

[mike-s]

Wine? or whine? At least Woodsy is making progress. As to the diode test, i'm not really sure. Just make sure you are certain which wire connects to which point of the rectifier. No good trying to test continuity across two different sides of the rectifier, it will never work!

[Woodsy]

i'm going to see what happens tomorrow morning i'm going to try and jump start it, maybe the cold nights outside has played its toll. If it turns out to be the battery is it worth trying a different battery setup? I dont want to throw a new battery at it only to have it drain down too

[pete]

Cool, I'm all out... and Mike...

Josh, definitely give it a jump and see what those volts look like at idle vs. 5K RPM etc.

Maybe disconnect the stator and do the AC test while you're at it. Is it possible you pinched one of the stator leads or something when putting the engine back in?

[mike-s]

Food for thought, i once had a rectifier have a diode crap out and instead of collapsing open circuit, collapsed and allowed bidirectional current, abeit at a rather low rate. Was why the battery only seemed to last a couple weeks before it was near dead flat. Fortunately i caught it in time and replaced the rectifier and also was able to recover the battery by recharging it in time.

[Woodsy]

Okay the bike will jump start and rev while connected to the other battery, once i remove the connection the bike dies or once i rev it the bike dies when the bike is relying on its own system.

Now if i disconnect the stator wires and jump start the bike it will run and rev, then i disconnect the jumper battery and if i connect the stator wires one by one while the bike is revving i can connect all of them bar the white and green one, once its connected and i touch the throttle it dies in the butt.

It also wont push start anymore, i spent about 30 minutes trying.

Me thinks its time to pull the stator out and take the cover off the wiring and check it all, being so old its all really brittle so it wouldnt surprise me.

[Woodsy]

Ok stator is off, i cant physically see anything wrong with it, but i am now getting resistance in the wiring of 01.2? and up to 02.2 in one wire.. going to borrow a battery charger tonight and leave it on overnight and see what happens, i have never had so many problems with something mechanical... but thats what you get when you buy an old bike i spose.

I'd like to say i'll hold onto the bike but at this stage i'm going to fix it, paint the rest of it and sell it and get something else before something else goes wrong with it.

[Woodsy]

Okay i retested the resistance of the cables as i broke the earth cable on my multimeter. doing the A-B B-C C-A test i get the same resistance of 1.5 on all cables. If i test each cable going to earth i get no resistance at all.

I also tested the regulator again for resistance as it says in my manual by taking the plug off it and testing each pin to another pin and get no resistance at all when i should be getting it.

The battery is on charge now, should be ready to go in the morning.

[pete]

Stator sounds good, the real test will be making sure none of them have a connection to frame ground once it's reinstalled and testing to see what the AC voltage is at about 5K RPM.

As to the R/R test... dunno. I tried it and can't remember what the results were now, but it was inconsistent with what the manual said it should be, in that the manual said look for voltage and I got resistance, or something along those lines.

My plan to test the R/R is simply to hook it up once I've verified the stator and see what voltage it puts out.

I think the diode test on my multimeter is done differently to what the test expects, but I may be wrong...

[Woodsy]

It Lives!!!

Stator is putting out in excess of 80acv at 5000rpm as it should be on every wire.

Maybe it was just the cold that stuffed the battery?.. Will be interesting to see if it fires up tomorrow morning, I'm tempted to park it in the garage overnight now although it is under a carport normally, maybe it needs a Blanky? lol

Got to get some new connections for the stator wires and hopefully its rock and roll time!