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Old 11-26-2012, 04:26 AM   #1
Colllyy
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Charging issue

My bike is not charging.

Tested regulator regulator's diodes using multimeter, not many of the ohmic values matched the table.

Tested alternator A/C output at 5000 rpm, not getting any reading.

Tested alternator stator resistances, all read as specified (0.2 Ohms).

Half functioning regulator may explain small amount of charging (reads 12.2 at battery, battery when engine is off at 11.8v)

However, not sure why I don't get any A/C readings. Regulator was replaced in August by a garage. Reluctant to replace again if there's an existing problem. Also reluctant to replace generator.

Are there any other tests or commonly known faults I should look out for?

Thank you
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Old 11-26-2012, 04:41 AM   #2
Slaki
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Re: Charging issue

Can only be one of the following things.

Bad rectifier
Bad Stator
Bad Battery

When the bike revs at 5000 rpm, what is the voltage at the battery?
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Old 11-26-2012, 05:12 AM   #3
Colllyy
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Re: Charging issue

At 5000rpm it reads 12.2
I get no A/C output from the alternator.
Can someone confirm the test for that with me please?
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Old 11-26-2012, 05:18 AM   #4
Knight2211
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Re: Charging issue

Quote:
Originally Posted by Colllyy View Post
At 5000rpm it reads 12.2
I get no A/C output from the alternator.
Can someone confirm the test for that with me please?
12.2 DC I assume you mean?

you understand that one is AC and the other DC, correct? The 12.2 DC that you would be reading is just battery voltage. If you have no AC directly off the alternator then that's where you need to be looking. Just make sure you're checking in AC.
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Old 11-26-2012, 05:54 AM   #5
Colllyy
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Re: Charging issue

hi yes, 12.2 dc on the battery.

Cant get an a/c reading off the the 3 yellow wires though... i am connect the red probe to one wellow then the black probe to another, is this correct?

thanks
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Old 11-26-2012, 06:06 AM   #6
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Re: Charging issue

Correct yes.

By the sounds of it your stator is fried.

If I am not mistaken you should get a +- 170 volts from the two yellow wires...
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Old 11-26-2012, 06:11 AM   #7
Colllyy
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Re: Charging issue

it should be 65v min and theres 3 wires....

as said in the first post, alternator resistance on all three yellow wires is in spec (0.2), if they were fried... surely it would give an infinite resistance reading???
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Old 11-26-2012, 09:28 AM   #8
rv6john
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Re: Charging issue

Quote:
Originally Posted by Colllyy View Post
it should be 65v min and theres 3 wires....

as said in the first post, alternator resistance on all three yellow wires is in spec (0.2), if they were fried... surely it would give an infinite resistance reading???
If they burnt open, then yes you would get infinite (open circuit). If the insulation broke down and the windings are touching then you could get a dead short (resistance 0). The winding can also short to ground (that check is in the manual also)

It sounds like you have the voltage check correct. Check each yellow wire to ground (should be open). If that is OK then pull the cover and take a look. I don't think it has been a problem with the GSXRs but some other suzukis have had the magnets come loose.
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Old 01-07-2013, 07:16 AM   #9
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Re: Charging issue

Sorry to bring this up again. . . Haven't been able to look at the bike for various reasons so only just opened it up. The coils and magnets look okay I think... Seen some videos/photos where a few coils are burnt, but mine aren't. Could I have some hint as to what I'm looking for? Thanks. Also would a photo help?
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Old 01-07-2013, 08:18 AM   #10
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Re: Charging issue

I just re-read your posts.

Are you sure you did the stator running test correctly? The meter leads plugged in correctly, meter set on AC (not DC) and you check all three pairs of wires?

I question this because it seems like you have some charging going on which means there must be some output from the stator.

Second, 11.8 volts at the battery with the engine off is a DEAD battery. 12.2 volts is an almost dead battery (45% charged).

For testing (and a happy bike), you really need to start with a good, charged battery.

If you have .02 to 1.0 ohm across all three pairs of yellow wires to the stator and there is no continuity between any of the three yellow wires and ground (the engine case) and the magnets are still intact, you will have output from the stator.
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Old 01-08-2013, 06:36 AM   #11
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Re: Charging issue

The stator winding resistance test is only good for checking for open circuit connections.

The AC no load test is the correct one to use to determine stator output.

Sounds like you have no output at all from the stator. If all the phases measure low DC resistance the stator most likely has short turns on virtually all of the phases and poles.

That is you have a fried stator. A visual inspection of the stator is required.
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Old 01-09-2013, 08:11 AM   #12
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Re: Charging issue

Yes, I did the tests correctly.
Ok what should I be looking for when I visually inspect the stator? I had a look but it looked fine... I'll do all the tests again once the battery is charged, but I'm sure I did them correctly.
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Old 01-09-2013, 02:42 PM   #13
Ecko508
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I haven't had any issues with my bike thank god, I'm at 3400 miles I'm wondering what I should do to prevent it if it so happens to arise


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Old 01-10-2013, 05:27 AM   #14
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Re: Charging issue

Sure your meter reads AC volts correctly?

If the stator windings looks black or charcoal then they have over heated and will have shorted turns. If they look good make sure your meter works correctly on AC waveforms that are not mains voltage frequency, i.e 50 or 60Hz. Do a test on another good working bike to check the meter is working correctly.

A shorted turn acts as a short circuit to the magnetic field, so it only takes one shorted turn on a pole to give no output from that pole. There are 6 poles to a phase and 3 phases, so 18 poles all up on the stator. I think the earlier GSXRs may have had 3x5poles.
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Old 01-15-2013, 10:22 AM   #15
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Re: Charging issue

What happens if you have one reading 18.2v at 3krpm. Does that mean the rectifier went bad.
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Old 01-15-2013, 12:12 PM   #16
rv6john
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Re: Charging issue

Quote:
Originally Posted by MelEvo View Post
What happens if you have one reading 18.2v at 3krpm. Does that mean the rectifier went bad.
If you mean measured at the battery, yes the R/R is done.
The battery is cooked also.

STOP RIDING THE BIKE RIGHT NOW!

Continuing to run the bike will fry the ECU and possibly other expensive components.

BTW, I just saw your post regarding your tach/speedo display. This might be cooked already. Install a new R/R and battery and cross your fingers.

Last edited by rv6john; 01-15-2013 at 12:14 PM.
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Old 01-15-2013, 06:08 PM   #17
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Re: Charging issue

If the resistances are correct on your stator, it makes no sense that you are getting zero volts on all three legs at 5000 rpm.

Make sure you have your meter set correctly to measure AC volts. Check this by putting the probes into a wall receptacle in your house. You should see 110 to 120 volts. If not, something is wrong at the meter.

Last edited by QuietRider; 01-15-2013 at 06:13 PM.
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Old 01-16-2013, 09:23 AM   #18
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Re: Charging issue

I fixed the issue I just wanted to make sure that was the issue. I rode on it for two month before noticing that I had a problem with it. The reason I realize that there was a problem is my HID didn't work and when I changed them to regular bulbs every time I rev the bike the bulb would get brighter and I would let go and the bulb would go dimmer. Thank god nothing else messed up. Yes the battery fried and I had to buy a new one, thats when I tested the voltage.
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Old 01-16-2013, 09:24 AM   #19
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Re: Charging issue

I have a stator at the house too but I'm gonna return it since I didn't need it.
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Old 01-28-2013, 02:19 AM   #20
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Re: Charging issue

Okay. Put it all back and it's charging now. Works fine.... HOWEVER I wonder what's causing it to fry the regulator? It's the third regulator since August now.
Last time it lasted a few months and then just died. I'm selling it soon and don't want to sell it "broken". What could be causing it?
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