Alternator issues HELP - GSXR.com
 
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post #1 of 7 (permalink) Old 04-15-2017, 04:35 PM Thread Starter
Squid
 
Join Date: Apr 2017
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Alternator issues HELP

Hi all, looking for help, pointers, and opinions please.

long story, short version. This is about a 1992 GSXR 1100, alternator keeps dying.

I fully charge the battery (lithium battery, using batter tender to recharge). Reads 13.4 volts.

Bike starts and runs well for approx 30 minutes, at which time the battery has depleted severely. Then bike starts acting up as if misfiring the dies when battery is depleted to 10 volts. Recharge batter, and same cycle starts. I am certain the misfire is due to the ignition system not getting enough volts.

Alternator in this bike has two wires (orange and red) coming out. I think it is the following:
ground is through the alternator body to chassis
red wire is power generated and should go to battery
Orange wire is battery feedback to alternator

Alternator Red wire reads 0.5 VDC (this is a problem since it should read 13.5 at idle)
Orange reads very close to battery level at that moment

The alternator has a problem, but then I had it checked and they replaced voltage regulator. Same thing still happens.

I am wondering if there is something in the bike that is killing the alternator. I checked all my connections and all seem good tight and without corrosion. I did find corrosion on the connection underneath the battery box feeding the + battery cable. Although ohm meter showed no resistance in that area, I did clean and grease it.

Any thoughts or suggestions? May be a test to find shorting circuits that I haven't been able to find? Anything?

1992 GSXR 1100
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post #2 of 7 (permalink) Old 04-15-2017, 07:33 PM
Racer
 
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There's more than a regulator in there. The stator in the alternator might have an issue. It has to be taken apart and leads disconnected from rectifier to get a proper ohm test reading.
Its been a long while but I think the orange wire is what tells the regulator what voltage it needs to regulate to.
The red goes to the positive on the battery.
Those sealed unit alternators can be tricky to work on.
Since they installed the rectifier, take it back, let them check your stator.

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post #3 of 7 (permalink) Old 04-16-2017, 07:17 AM Thread Starter
Squid
 
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Yes will be asking it back on Monday.
In the meantime, I am looking for tests to conduct on the bike to certify it is not going to kill the next alt.

I did a drain test, although I knew battery was not draining by itself, but that also (I think) confirms that there is no circuit shorting. Oddly enough, while drain tolerance is 0.1 mA I have 0.0 mA which is perfect.

I am about to disconnect and trash my old Ungo alarm system just in case something strange within it is causing my problem. The alarm cover case has long disintegrated and may get water on its circuit board. But that probably should damage the alarm system itself, not the rest of the bike electrics.

No?

1992 GSXR 1100
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post #4 of 7 (permalink) Old 04-16-2017, 08:15 AM
Racer
 
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If that alarm use protected, it shouldn't be a problem.
An alarm armed is always a battery draw though.
That bike has years on it, I suspect that's the only reason it is bad.

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post #5 of 7 (permalink) Old 04-18-2017, 08:05 PM Thread Starter
Squid
 
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Okay so alternator is back in the shop, haven't heard from the yet.
In the meantime, I have checked all connections and have not been able to find loose or corroded connections.
I was under the impression that these sealed unit alternators were good for 2-300,000 +, I only have 45,000 km.

Is this possible:
I am using lithium battery for the past 4 years, takes little effort to charge. Could the alternator be transferring all the unused energy into heat and that has become excessive enough to kill itself?

1992 GSXR 1100
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post #6 of 7 (permalink) Old 04-18-2017, 09:39 PM
Racer
 
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With that alternator and a Lithium, I have no idea. But a regulator/rectifier would go bad before a stator if it was dumping voltage back to ground I would suspect.

I know when you install an aftermarket reg/rectifier on those, if they painted the reg/rect, you have to scrape off the paint where it grounds on the mating surface.

Installed a reg/rect on a buddies bike an it wasn't working right until we scraped that paint near the bolt holes and it grounded correctly.

Not sure if that's an issue on yours or not.

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post #7 of 7 (permalink) Old 04-21-2017, 02:33 PM Thread Starter
Squid
 
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Update!

Shop called me today to tell me that the alternator now has burnt Regulator AND Rotor. There is no warranty on the previous work because it is electronic stuff and they blame the bike to have something that is causing the alternator to burn out.

I am at a loss here, whether they just don't know how to fix it (this is a large shop where all the smaller alternator shops in the city send their work) or something really wrong with my bike.

Any suggestions what I should do? Take it to Suzuki dealer, maybe they warranty it?

1992 GSXR 1100
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