I have a 97 GSX R600, recently my battery has been running dead. Battery is still good and changed rectifier about 3-4 months ago. I thought it was my altenator/stator so I switched altenator with my other srad and cranked her up. After about 5 minutes the black wires near the rectifier were hot (started to give off a little smoke). I cut the bike off and have now completely stripped my bike (took altenator and rectifier off). The wires that were hot were not attached to rectifier but on the other end. It appears these are the same black wires coming from the altenator. Thinking about purchasing new altenator, any suggestions?
Check the battery connections, then buy a digital voltmeter for about $20. That can tell you what's wrong. You'll also need a manual with your voltmeter to test the battery, alternator, R/R, fuses, and wiring. I don't know about you, but I would be pretty upset if I replaced the alternator and it still didn't work right.
Last edited by No Worries; 01-11-2008 at 12:46 AM.
ok, tested both stators/altenators and they both appear to be ok according to the readings:
Ground to terminal ends no continuity= good
Ground to coils no continuity= good
resistance on all wires from altenator to rectifier all read about 4-5ohms=good
Rectifier is not giving any readings at all= bad?????
I tested my previous bad rectifier and the other two rectifiers I have, all are giving no resistance/ohms readings at all. Does that mean that all my rectifiers are bad? Also, could something be burning out my rectifier?
The only thing I can think of right now is to test the voltage output from my altenator/stator. Could this cause my rectifier to burn out?
Good testing. Your rectifier, regulator, or alternator may be bad. Or it could be the battery or wiring. Alternators are expensive. There should be a test in your manual to remove the regulator wires from the alternator circuit to see the output from the alternator, which should be around 16 volts at 5K. The regulator changes excess current to heat.
The rectifier changes AC to DC. The diodes are one-way valves and there should be a test in your manual for the rectifier. Any stinking rectifier/regulator should work in your bike. They all work the same. The problem is in the colors of the wires. Each manufacturer uses different colors. If it's hooked up wrong, major damage.
Almost any Suzuki R/R should work on your bike with the correct wiring plug(s). If you can find one from a junked Suzuki, just don't go back too far. My 79 GS used a separate rectifier and regulator. Or borrow a friend's R/R. Most are plug and play.
I would say the stator is bad. That's not putting out the voltage it should at revs. Your rectifier is only a slave to what it has. However there are ways to test the stator. If it passes and the wiring is fine... then the only thing left is the rectifier, which is hard to troubleshoot by any other means other than "the process of elimination" to the other components.
Ok now... Bike is running off my battery and battery appears not to be charging. Battery is dead again after 30min of riding, unhooked my lights and it cranked up. altenator/generator will be next purchase... should I go new or used?