Help,
98 GSXR 750. I have fried the rectifier and wires twice. Icould definetely use help!!! If anyone has any experience with this I could use your help.
Thanks!!!
Tim

[ 01-06-2002: Message edited by: TimW ]</p>

describe the part... Im not sure what it is... If you can discribe it then I might have an idea what to do.

John

This happened to me on my standard. The wire that goes to the rectifier ( i think it;s the wire that decides how much current goes back to the battery and how much to the coils). So I cut the wires, then crimped it with a crimp kit. If you don't have one, you can just solder it together. I think we get a bad connection at the harness b/c a bunch o crap grows on them, increasing resistance. I think then, just washing the contacts out every once in a while should work too but who wants to wash it out every so often? Wouldn't you rather ride?

87' yamaha radian left me stranded two wks ago b/c of this problem. Luckly, I have great friends that also carry tools in their cars.

I'm not sure if this is what you are talking about, but on my '99 there are two wires that run to the rectifier I believe. They are both run through a small square black plastic connector. The connector is what got fried, so all that needed to be done was to remove the fried wire from the connector and give it its own crimp connector, bypassing the plastic square.

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by GdSaXnR:
I'm not sure if this is what you are talking about, but on my '99 there are two wires that run to the rectifier I believe. They are both run through a small square black plastic connector. The connector is what got fried, so all that needed to be done was to remove the fried wire from the connector and give it its own crimp connector, bypassing the plastic square.<hr></blockquote>

Was there only two wires going to it, or was it only two of them that got fried? I had a problem like this but the harness had 5 wires in it. Two of them were melting the plastic. I took all 5 and just soldered them. Got ride of the plug all together.

John

could be a defective altenator giving out too much charge , as it goes through the rectifier before reaching the battery.
could just be the wires were loose in the connecter block

I think I can help you. I'm an electrician in the air force, and I have the manual for your bike from suzuki. (I came with the manual for my 96 GSXR 750) Your rectifier should have five wires going into it. Three black, one red and one black with a white stripe. It's on the left side of the bike, right above the passenger pegs. IT IS VERY IMPORTANT THAT YOU DO NOT CUT AND CRIMP ANY OF THESE WIRES TOGETHER, THEY ARE ALL VERY IMPORTANT. I'm going to e-mail you some info that will help you.

When does it happen? When your riding down the street, or when you start the bike. Are you having any other electrical problems?

Let me know, I don't have a long background with engines, but I know my shit about electricity.

Rob images/icons/tongue.gif

Where do you stay in AZ. ? I'm in Phoenix, at Luke AFB. E-mail me.

Rob

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by GSXR-Freak:


Was there only two wires going to it, or was it only two of them that got fried? I had a problem like this but the harness had 5 wires in it. Two of them were melting the plastic. I took all 5 and just soldered them. Got ride of the plug all together.

John<hr></blockquote>

I don't remember exactly, my dad is the one that fixed it while I was at school. He showed me everything he did, there was two or three wires in the black plastic connector and one of them heated up enough to melt the connector and make contact with one of the other wires in the connector. So he just removed the hot wire and crimped a separate connector on it. So it was really only one wire out of the two or three that got fried but it was making contact with the other. It ended up causing my whole charging system to go whacked and the bike died.

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by rjohnsoniv:
IT IS VERY IMPORTANT THAT YOU DO NOT CUT AND CRIMP ANY OF THESE WIRES TOGETHER, THEY ARE ALL VERY IMPORTANT. <hr></blockquote>

Why not??? What is the outcome if you do? It is just like having the plugs on there but you can not unplug them. Please give me info so I know if I should redo mine some other way.

John

I think I can help you. I'm an electrician in the air force, and I have the manual for your bike from suzuki. (I came with the manual for my 96 GSXR 750) Your rectifier should have five wires going into it. Three black, one red and one black with a white stripe. It's on the left side of the bike, right above the passenger pegs. IT IS VERY IMPORTANT THAT YOU DO NOT CUT AND CRIMP ANY OF THESE WIRES TOGETHER, THEY ARE ALL VERY IMPORTANT. I'm going to e-mail you some info that will help you.

When does it happen? When your riding down the street, or when you start the bike. Are you having any other electrical problems?

Let me know, I don't have a long background with engines, but I know my shit about electricity.

Rob images/icons/tongue.gif

I know this is a really old post but I have a 99 750 that I need to rewire the rectifier. The original is burnt, it toasted the wire harness witch I had to cut the plastic off completely on both sides (from stator and rectifier). I know the connection scheme for these because I thought that would solve the problem. Well the old rectifier still wont work so I need to know which wire does what so I can hard wire the new rectifier. There are 3 solid black wires and one red and black and one yellow(white) and black, I can be a little color blind. Any Helpers??

The 3 black wires are AC from the stator going into the rectifier which converts the AC to DC that comes out on the RED= + and Black = Neg. Rect. should output 14-15 VDC to charge the battery. The ac measure 65vac @ 5000 rpm no load. I am having the same problem. I already cut out the connectors and ran new wires. also replaced the stator and 2 rectifiers and still the wires draw 28 amps and the AC side drops to 4-6 volts and they start to melt with the DC side of the rectifier disconnected. The AC side seems fine no load until I connect the rectifier. I even put ceramic resistors across the 3 ac outputs and the voltage held steady and it put out 3 amps. any ideas about this problem would be welcome.

It sounds like you have a issue with the R/R's you are using. Are they new or e-bay items?

John

the first rectifier was used. but the one in there we bought new and a stator also.

Have you used the factory service manual to test the R/R and make sure that it passes the test? Even new, they can fail.

John

Yes. I just checked again and both the stator and rectifier read within the values the service man shows as good.

Then I would have to assume that you have a short someplace on the bike.

John

there is no electrical connection right now between the bike and the rectifier. I disconnected the 12vdc output. the bike is running only on battery right now. I just talked to the guy who sold us the rectifier and he is going to take it back and test it.
He also advised running #10 from the DC output straight to the battery through a 30a fuse bypassing the harness. I did that and I did get a 14,9VDC charging voltage across the battery. Problem is the stator wires still heated up putting out 21amps at 12VAC. When I increased the rpm the the voltage dropped to 10VAC and put out 28 amps heating up those wires even more. I could also increase the size of those wires to handle that load if this is normal but the 6" leads off the stator will still get hot.

I can say from experience that there is usually more than meets they eye when it comes to regulator/stator problems on these bikes.
The harness often gets cooked in areas that we may not see only to wreak havoc on our newly installed regulators & stators. The sheathing gets melted and wires become exposed and fused together in places we may not have discovered yet. I have had this happen on several Srads and a new gen as well. Don't overlook trouble shooting the harness as well as looking for exposed/cooked wiring up line from the regulator as that's usually where the problem resides.

I agree with The SRADIATOR. I just had this happen to me last week. The wires were cooked about 2 inches away from the R/R because they were laying on the cylinder head. I believe they got so hot from that in addition to the heat from the R/R itself and the bike just died. I replaced the R/R, cleaned the harnesses and added foam insulation around the wires and harnesses. I also installed a computer fan on the side of the R/R to push air from the outside into that area to help further cool it down during the stop and go in summer heat.
Cheers!

wow bringing an old one back again

wow bringing an old one back again

Some things (carb issues, c.c.t. failures and wiring woes) remain timeless!

Damn, a 10 year old thread.....winner winner chicken dinner

Damn, a 10 year old thread.....winner winner chicken dinner

You know how Canadains are...never in a rush for anything!