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Old 01-10-2008, 11:01 PM   #1
atalien25
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SRAD Electrical Issues

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?
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Old 01-10-2008, 11:44 PM   #2
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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; 01-10-2008 at 11:46 PM. Reason: spelling
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Old 01-11-2008, 02:51 AM   #3
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Or most major auto parts stores that also dable in moto parts will test them for you! Just to be sure before you throw down the money for an alternator!
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Old 01-11-2008, 08:19 AM   #4
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Thanks for the info, I have a voltmeter and manual... I will give updates later
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Old 01-11-2008, 10:13 AM   #5
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Test Results

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?

Last edited by atalien25; 01-11-2008 at 10:15 AM.
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Old 01-11-2008, 10:17 AM   #6
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If you dont have the haynes for your bike yet I got it from a link in a post on ether gsxr.com or gixxer.com as a free download!
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Old 01-12-2008, 11:04 AM   #7
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Generally, if your wires are getting hot you have a bad connection. Bad connection creates more heat.

However, once you rule out the stator, the battery and wiring it is usualy the VR. (voltage regulator aka rectifier)

Did you check the voltage on the battery with the motor off? Should be abt 12.8 then when you start the bike it should read 13.5 - 14.0
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Old 01-15-2008, 05:45 PM   #8
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actually I did a few days when I started noticing my flickering lights. With the bike off, from what I remember I know it was more than 15 volts.
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Old 01-16-2008, 08:21 AM   #9
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15 volts
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Old 01-27-2008, 09:02 PM   #10
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update

So I finally put my bike back together... Rectifier tested good and Stator tested good. Well, I turn the bike on and warm it up to test the voltage.

Bike off- 12V
While cranking- 10.5-11V
Idle- 12.5
5,000 RPM- 12.5-12.8V (Is this normal)

Head light seem to flicker during acceleration (winding up RPMs).

Is my stator bad? Shouldn't it read 13V+ when at 5,000 RPMs?

Will ride bike all day tomorrow, if battery dies I can safely assume stator is bad?
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Old 01-27-2008, 11:52 PM   #11
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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.
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Old 01-28-2008, 01:44 AM   #12
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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.
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Old 01-28-2008, 01:44 AM   #13
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But I must disagree with NW on "any rectifier should work" because there are different amperage ratings for them.
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Old 01-28-2008, 01:04 PM   #14
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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?
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Old 01-30-2008, 12:17 AM   #15
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New... sorry
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Old 02-27-2008, 03:34 PM   #16
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Quick question... My stator wire that clips into my rectifier is hot and has melted the connector plug... Bad rectifier is what I have been told, tested fine with meter.
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Old 06-20-2008, 05:56 PM   #17
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So my plug is still melting. New rectifier and replaced stator....
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Old 07-04-2008, 07:11 PM   #18
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I'm having the same exact issue with a 1998 750.
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