Gsxr 750 k2 charging system problems

[Pedro1974]

Hi All

Bike: Suzuki GSXR 750 K2
Standard, no mods

I’m having problems with my charging system and have exhausted my limited knowledge and am in dire need of some help!!!

The first sign of problems was blowing headlights and a hot, warp and smoking battery. I’ve tried the following solutions but no joy as yet:

1) Replaced battery - extremely hot, smoking, swelling.
2) Replaced rectifier/regulator - the connection to the wiring harness had melted.
3) Replaced the generator/stator - the old one looked fine but changed it anyway.
4) Checked/cleaned all the writing harness and connections -

I found 2 orange cables from the right hand side of the harness under the front fairing that were burned and mangled, so removed the damaged areas and connected new wiring to the connectors.

I was sure that these 2 wires were the culprit but the battery is still showing 17-18 volts when running.

I searched every loom, conduit and connections for corrosion but everything else looks fine.

I’ve tested the Replaced battery, generator and rectifier in case they were dodgy but all are reading good on a multi meter. Even measured the old battery and rectifier the volts and diode test showed they were faulty.

Does this kind of problem ring any bells with anyone or can anyone point me in the right direction, I would be eternally grateful.

Thanks for reading my post
Cheers

[sickpup]

It's the reg/rec.

[Kawasaki Jimbo]

[Easy-X]

Yeah, 14 volts or so would be what the battery is wanting. Generally the point of a regulator is to have a varying input and smooth it out to a constant voltage. A rectifier just converts AC to DC, it doesn't stop the voltage fluctuating.

Not knowing the specifics of your bike (sorry) I can only suggest if it's actually a regulator you're talking about then it's faulty. If on the other hand it's just a simple rectifier circuit then it leads back to the generator/alternator/magneto/magic-spinny-spark-thingy.
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[sickpup]

Looks like the K2 uses a simple 5 wire combined reg/rec.

As you have wriing loom damage you need to change the way the reg/rec is wired in.
1. The three wires from the Alternator, leave them as they are and plugged into the main loom.

2. The two wires that don't go to the Alternator, one will be live and one earth. Remove these from the plug and wire them directly to the battery via cable that can handle at leat 45amps with an inline 30 amp fuse.

Now check the charging volatge, if too hight the reg/rec is shot so replace.

Alternators don't fail by producing more power.

[Pedro1974]

Thank you all for replying so quickly and giving such great advice. I’ll go and purchase some wiring with an inline fuse and i’ll let you know the results.

Thanks again
Pedro

[Pedro1974]

Hey Guys

I’ve not had much change to tinker with the bike for a while, hence not replying sooner.

The regulator/rectifier from Amazon was the culprit! After spending hours cleaning and checking all the wiring loom connections etc, it turned out the be the very first thing I tried as soon as I started having the problem!! I did a bias and reverse bias test on the Amazon one and all was fine so it didn’t occur to me that it could still be the R/R.
I found an second hand original R/R that came off a gsxr as there isn’t an electrical shop that sells 45amp cable near me and hey presto. Problem solved.

Top tip - don’t rely on the cheaper parts even if it’s from a well known shop (Well, Amazon).

Thanks for pointing me in the right direction guys. Seriously, without it, I would still be going through the wiring loom, cursing why I even bought the bike

[Easy-X]

Lol... another thread resolved via regulator replacement!
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[sickpup]