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Discussion Starter #1
Hello,
Having an issue with my charging system (GSXR1100 1986.

Even after modification done as described in picture coming from OldSkoolSuzuki
and a new regulator installed,type as picture

I still read 16-18 V DC over the battery when engine is running on 3000 RPM and above
I had the same numbers with the stock regulator, so no difference using the new one
Is next step to find a new or used alternator or are there other things to check prior to replace the alternator completely?

Thanks
Magnus
 

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Not have any experience with the regulator but if the alternator is pumping out up to 18v then I would guess there's nothing wrong with it. (the alternator) unless there is an internal regulator to alternator connection issue

Check for voltage drop measure at the battery to ground (frame) and again at the alternator orange wire connection to ground.

With that mod it is supposed to take out all the possible places a voltage drop could occur and have a direct feed to the alternator

You could run a wire direct from the battery to the alternator to make sure there is no voltage drop and measure the out put voltage again. Other thing to look at is the earth connection at the motor and the battery.

This what I'd do check all the connections you have made including the connections between the regulator and the alternator to make sure they are all good clean and supplying full voltage and crimped against the wire not the outer plastic etc

I don't know if this is any good for you as you need a variable voltage source to test the regulator
 

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idiot
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Quoted here for prosterity and taken from Electrosport page many years ago. Page no longer exists to the best of my knowledge

TECHNICAL ISSUE DETAILS
This Suzuki uses a "car-type" alternator that is mounted behind the cylinder block. Inside this alternator there is a field rotor with copper slip rings on which carbon brushes run. Around the rotor you will find the stator and in the front of the housing are the built in rectifier bridge and the electronic voltage regulator. Common faults: FAULT 1: OVERCHARGING THE BATTERY. This is usually caused by (1) a bad internal voltage regulator or (2) a bad electrical connection somewhere on the bike in the lead that provides battery voltage feedback to the internal voltage regulator (the voltage "sensing" wire) The replacement voltage regulator is our part# ESR025. This unit replaces the OEM unit even though it looks different. To find the bad connection to the voltage "sensing" wire you need to look at the leads coming from the alternator. There is one large diameter lead, usually RED, that is the output from the alternator to the battery. The thinner lead is the sensing wire for the regulator. Use a multimeter to measure the voltage on this lead to ground. It should be close to the battery voltage with the bike running (around 14Vdc). If you see a substantial difference (say: battery voltage 17Vdc, sensing lead 14Vdc)you should look for a bad connection somewhere between the battery and this sensing lead. Inspect all connections, the ignition switch, use spray contact cleaner on everything. Spend some time and you will probably find a bad connection somewhere. Fixing this connection should fix your overcharging issue. FAULT 2: NO OR LOW BATTERY CHARGING. This can be caused by a bad internal voltage regulator inside the alternator, or by a bad rectifier module. A bad voltage regulator sometimes is caused by a shorted out field rotor that is drawing too much current from the voltage regulator. Inspect the rotor resistance between the slip rings which should be 3.3-4.0 Ohms. Another cause could be bad connections between the alternator output and the battery terminals. Check all connections and see if this fixes the issue.
 

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Discussion Starter #4
Thanks for the input:)
Problem solved, my own mistake. Managed to pinch one of the cables from the new regulator against the alternator cover.
Fixing this resolved the issue. Now I have steady 14 V DC over the battery poles.
 

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idiot
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You are cutting out a lot of excess wiring/switches/connections (i.e. causes of volt drop) in the sensing wire. Volt drop in the sensing wire will cause over charging of the battery. (Something along those lines)



OP where did you get the regulator from? OEM?
 
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