charging issue GSXR-750 '91

[dingo]

hi guys , thought i might pick some brains before i start strippin
the beast , went to get on the bike again yesterday and saw
the battery was flat,funny cos i have been havin daily rides for weeks
(new gel cell and the bike has been goin without
a hicup)so i give it a jump off the 4x4 and it ran fine for 10 min odd,
reading bout 13.5v ? , then the circut breaker popped (bike started
to run erratic) stopped it , pushed the button back in and still no start
so i jummped it again ,run for a bit then the button pooped again on a big
rev and i then saw a tad of smoke from the plug from the alternator wires
(they were really hot)has anyone had this issue before? or are there any
thoughts as to where to start. i also had the battery hooked up to the bike
as normal and put the charge on it over night and thismorning it wouldnt crank over at all.
thanks heaps
Carl

[Chase]

Had a similar issue with my 1100, turned out to be the regulator. You can get a small wire in regulator from most bike shops that sits inside the stator same as;

http://www.1tail.com/Electrical/Suzuki_GSXR1100_Regulator_&_Rectifiers/

Pretty simple to install - the heated wires could be from the overflow of charge running back through the wires. From memory they cost about $60. Prob one of the cheaper tests to see.

[dingo]

thanks Chase, i just been out there testing and visually lookin over everything,
i cant find any shorts anywhere and everything looks good exept the plug from the
alternator and the red wire imeditatly following it, the orange wire is fine ,
just the red one is melted, its just strange that it all of a sudden started to
do this (i guess all problems start sometime hey :)), but how would that cause
the battery to go flat? is there a regulator inside the alternator? , any notes
on how to test them? may have to look into one of those , cheers for the link :D

edit-the wire that is melted is the one thats connected to the soldered one at
the alternator inside (not the screwed on one)

[Chase]

If you chuck a multimeter on the + wire coming from the alternator and rev the bike you will prob see the the voltage jump up around 18v (or no volts) if it's a reg, one of the side effects of a fkd reg can also be that it destroys the battery cause the continual overcharge sent through from the alternator fries the cells. Did you notice if the battery was hot after riding?

[dingo]

i did notice the volts jump up wen i give it a massive rev just prior to the button popping,
i didnt notice the temp of the battery on the last ride.

[Chase]

Prob worth charging the battery up then trying to start the bike and with the multimeter on the battery and see if the volts drop. When I did mine I thought the battery was fine cause it charged and looked fine -but when put under load the volts dropped and went back to looking charged when no load was on it.

[dingo]

cool , i had the battery on the charge for a few hours now , i will leave
it a few more and try it later, i thought it was odd to be on the charge
all night and not crank the engine over, it hasnt missed a beat till yesterday
thanks heaps for your thoughts Chase , stops one from pulling hair out thats not
there :D

[Chase]

No dramas, good luck. ;)

[dingo]

will post up later how goes it :D

[Redmohawk]

try loading your battery up after charging it still on the bench, put the multimeter on it and put a load on it to say a 12 volt compressor or spotlight or something like that anything that will draw 4 or 5 amps and watch the volts , if it drops heaps say to 10 v you have a dead cell in the bat.

[dingo]

got round to the battery again , been flatout, shes stuffed :(
on to finding where the cause is , will post up wen i find it

[Mishdog20]

Def sounds like the Regulator mate.

[dingo]

quote:Originally posted by Mishdog20

Def sounds like the Regulator mate.

i save the pennies and get on to it :)
too bad i aint got the missus nsr regd yet,
be sweet to hoon round on , soon [:P]

[Chase]

The internal reg I chucked in mine is still working a treat, you can also wire in an external reg (same as the ones they used to use in the old Holdens) - takes a bit more space under the seat, but they're only about $15. If you need the number I think I have one floating around.

[dingo]

quote:Originally posted by Chase

The internal reg I chucked in mine is still working a treat, you can also wire in an external reg (same as the ones they used to use in the old Holdens) - takes a bit more space under the seat, but they're only about $15. If you need the number I think I have one floating around.

$15 job sounds sweet(makes me sound like a real tight ass hey, i will
buy one of them other ones wen i can afford it) the part number and any
diagrams would be awesome if you got them Chase - cheers :D

[Chase]

quote:Originally posted by dingo


quote:Originally posted by Chase

The internal reg I chucked in mine is still working a treat, you can also wire in an external reg (same as the ones they used to use in the old Holdens) - takes a bit more space under the seat, but they're only about $15. If you need the number I think I have one floating around.

$15 job sounds sweet(makes me sound like a real tight ass hey, i will
buy one of them other ones wen i can afford it) the part number and any
diagrams would be awesome if you got them Chase - cheers :D
No dramas, I'll post it up tonight when I get home.

[dingo]

no rush , i still need to get another battery, least i can get it ready [:P]
Thanks :D

[Chase]

The regulator is a Bosch RE55

http://www.asfphotos.com/upload/1274831226.jpg


http://www.asfphotos.com/upload/1274787953.jpg


Just wire it between the red current wire coming from the alternator and the battery.

[dingo]

sweeeet [:P] , thanks heaps for the input and help Chase (and others :D)
i shall wire one in and let you all know how goes it once the new battery is in [8D]

[Chase]

No prob mate, hope it sorts it for ya. ;)

[dingo]

well i finally got a new battery and the RE55 regulator , wired it
in properly and the overall output was around 14-15 volts after the reg.
before the reg reached in exess of 25volts? and REALLY heated up the reg. ,
then a mate came over and i started it up to show him and nomatter wot i did
i could not get it to read more than 15 volts from the alternator and after
the regulator, so yes it works but im worried i will end up riding a fireball
as quick as it fixed itself , may try the first option you posted up chase , in
the meantime a big thanks for the help guys, and to scottymac and his parts box
for gettin me riding again for now.
Cheers guys

[Chase]

At least you're moving again mate. You should be cool with the RE55 reg until you can get the other one, had one on mine for ages. If you're worried about a high output just take it for a decent run on the hwy where you can get some revs up for a period and check the battery to see if it feels hot - it's a good indication that the volts are too high.