2006 GSX-R 600 Regulator/Rectifier & Charging Issues - GSXR.com
 7Likes
  • 1 Post By endoftheline
  • 1 Post By rv6john
  • 1 Post By Ozsyd600
  • 1 Post By Ozsyd600
  • 1 Post By PaulPhilly
  • 1 Post By Ozsyd600
  • 1 Post By Ozsyd600
 
LinkBack Thread Tools Display Modes
post #1 of 20 (permalink) Old 06-25-2019, 01:28 AM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
2006 GSX-R 600 Regulator/Rectifier & Charging Issues

Hi all,

I have a 2006 GSX-R 600 with approx 25,000 kms on it, it is in excellent condition.

I recently went to use it after it sat for 3 weeks and it wouldn't start - dead battery. I charged the battery and checked voltages from the battery with the following results:

Bike off / no key inserted - 12.39 volts
Key in, ignition on, killswitch off (ie: only lights on): 11.9 volts
Key in, ignition on, killswitch on (ie: just after fuel pump has primed): 11.75 volts
Bike running, only just started - 11.75 volts
At warm temperature idle around 15 minutes after starting - 11.36 volts
At 5,000 RPM in neutral - 11.18 volts

I tested the ohms reading on all possible combinations of the stator connector plug. When plugged in it initially showed a number and after a second all went to 0, so I am going with the reading being 0.

I was very briefly able to perform the unloaded test at 5,000 RPM and saw what looked like good numbers before the bike wouldn't run any longer due to the dodgy battery. I am waiting on a new battery to repeat this test.

I tested my regulator/rectifier and posted the results and members on another forum said that it was bad, so I replaced it with a brand new, genuine Suzuki part and received almost identical results. This would lead me to believe the issue is NOT the regulator/rectifier - am I wrong?

Looking at the data below, does this suggest the reg/rec is in a normal working condition? Or does it suggest there is an issue?

Regulator/rectifier readings:


Last edited by endoftheline; 06-25-2019 at 01:48 AM.
endoftheline is offline  
Sponsored Links
Advertisement
 
post #2 of 20 (permalink) Old 06-25-2019, 03:35 AM
Rider
 
PaulPhilly's Avatar
 
Join Date: Jul 2018
Posts: 410
You can ohms test the 3 leads from the stator. test all 3 leads so do 9 test every combo they should all be the same . I’m guessing you looked at the harnes and batt terminals already for broken wires and plugs.
PaulPhilly is offline  
post #3 of 20 (permalink) Old 06-25-2019, 04:46 AM
Lifetime Premium
 
rv6john's Avatar
 
Join Date: Mar 2013
Location: In the twisties around Hendersonville, NC
Posts: 7,989
The first battery voltage numbers show a weak or discharged battery. I would charge it and try again. A good test is to check the battery voltage while the starter is cranking the engine as a quick load check. The battery should be able to sustain 10.5 volts.

What do you mean by "good numbers" on the unloaded stator test? Also, you did not mention that you checked for stator coil grounding.

Here is an explanation of the system and the tests. Let us know what you find.

https://www.gsxr.com/13-tech-perform...tem-101-a.html

Quote:
Originally Posted by Chuckster View Post
If you think reading is tricky, how the hell are you going to follow troubleshooting directions?
"Riding well is difficult, riding poorly is easy and painful."
- Nick Ienatsch


"We're all here because we're not all there" - Guy Favron on Gold Rush

K6 750
rv6john is offline  
Sponsored Links
Advertisement
 
post #4 of 20 (permalink) Old 06-25-2019, 01:57 PM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
To me the original r/r looks like itís ok. Flip it over. Are there any signs of it blowing out - wiring sticking thru the resin?

The voltages with the bike running show that the bike is not charging. Forgive the stupid question, but you did plug the stator into the r/r and the r/r into the harness after doing your testing didnít you?

Do an AC voltage test on the stator. Should be at least 65V AC at 5k rpm with no more than 10% difference across all 3 sets of readings. From what youíve described you wonít see more than 19V AC when you do this test.

I agree your battery is badly discharged. If you canít charge it to 12.8V itís probably sulfated and dead.

I am suspecting your stator and battery will need replacing and youíll end up with a spare r/r. Do the tests and weíll know.


Sent from my iPhone using Tapatalk

Is it June yet?
Ozsyd600 is offline  
post #5 of 20 (permalink) Old 06-26-2019, 01:33 AM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Quote:
Originally Posted by Ozsyd600 View Post
To me the original r/r looks like itís ok. Flip it over. Are there any signs of it blowing out - wiring sticking thru the resin?

The voltages with the bike running show that the bike is not charging. Forgive the stupid question, but you did plug the stator into the r/r and the r/r into the harness after doing your testing didnít you?

Do an AC voltage test on the stator. Should be at least 65V AC at 5k rpm with no more than 10% difference across all 3 sets of readings. From what youíve described you wonít see more than 19V AC when you do this test.

I agree your battery is badly discharged. If you canít charge it to 12.8V itís probably sulfated and dead.

I am suspecting your stator and battery will need replacing and youíll end up with a spare r/r. Do the tests and weíll know.


Sent from my iPhone using Tapatalk
No, the reg/rec looks in perfect condition.

The voltage figures in my first post are all from before taking the bike apart.

The ohms test was done yellow wire to negative.

I didn't have enough time to do the unloaded test fully, as the bike cut out. But the first lead I tried showed close to 65vac from memory.

I've purchased a new battery and now need to wait until tomorrow till I can plug it in and do the unloaded test fully again.

Will post back once I have a further update.
Attached Thumbnails
reg-rec (1).jpg  
rv6john likes this.
endoftheline is offline  
post #6 of 20 (permalink) Old 06-26-2019, 02:33 PM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
Quote:
Originally Posted by endoftheline View Post
No, the reg/rec looks in perfect condition.



The voltage figures in my first post are all from before taking the bike apart.



The ohms test was done yellow wire to negative.



I didn't have enough time to do the unloaded test fully, as the bike cut out. But the first lead I tried showed close to 65vac from memory.



I've purchased a new battery and now need to wait until tomorrow till I can plug it in and do the unloaded test fully again.



Will post back once I have a further update.


That r/r looks ok and the readings you took seem ok too.

Iím betting the stator is dead.

It would be worth measuring resistance between each of the 3 stator wires and ground. Should be infinite resistance. And between each pair of stator wires. Should be a low resistance (donít have the numbers at hand), but not zero resistance.

I look forward to hearing your update with the new battery in.


Sent from my iPhone using Tapatalk

Is it June yet?
Ozsyd600 is offline  
post #7 of 20 (permalink) Old 06-26-2019, 10:59 PM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Quote:
Originally Posted by Ozsyd600 View Post
That r/r looks ok and the readings you took seem ok too.

Iím betting the stator is dead.

It would be worth measuring resistance between each of the 3 stator wires and ground. Should be infinite resistance. And between each pair of stator wires. Should be a low resistance (donít have the numbers at hand), but not zero resistance.

I look forward to hearing your update with the new battery in.


Sent from my iPhone using Tapatalk
Okay well now I am really confused, as I put in the brand new battery (which was showing 12.5 volts out of the box) and did the stator tests with the following results that conflict my earlier tests:

Stator 3 wires to negative battery terminal

All three wire tests eventually made it to 0.00 after a few seconds. Once the voltmeter first made contact between wire X and negative terminal, it showed a slight reading and then after 2 seconds or so it went to 0 and stayed at 0.

1: 0.00
2: 0.00
3: 0.00


Stator Ohms Resistance check
Wire 1 to Wire 2: 0.04
Wire 1 to Wire 3: 0.04
Wire 2 to Wire 3: 0.05


No load stator test:

Bike cold (running for 30 seconds or so), highbeam on, 5000rpm


With my voltmeter set as pictured as below, I was getting stupidly low readings like 04.5 across most of the connections and on some of them no reading at all. So now I am thinking I either had my voltmeter on the wrong setting initially or somehow I got my numbers mixed up with something else, as when I was able to very briefly run the bike the other day with the old battery I could've sworn I got numbers closer to 60.

So from these results, it would indicate a failed stator, right?

And my regulator/rectifier results are normal?

If so I'll be returning the brand new reg/rec and swapping it for a brand new stator...
Attached Thumbnails
meter.jpg  

Last edited by endoftheline; 06-26-2019 at 11:07 PM.
endoftheline is offline  
post #8 of 20 (permalink) Old 06-27-2019, 03:17 AM
Lifetime Premium
 
rv6john's Avatar
 
Join Date: Mar 2013
Location: In the twisties around Hendersonville, NC
Posts: 7,989
From your picture, you have the scale set right to 200V AC but you have the ground lead in the wrong socket. It should be in the COM socket.

I'm not sure what you mean on your first check to the battery negative. You say voltmeter, but you are measuring resistance.
endoftheline likes this.

Quote:
Originally Posted by Chuckster View Post
If you think reading is tricky, how the hell are you going to follow troubleshooting directions?
"Riding well is difficult, riding poorly is easy and painful."
- Nick Ienatsch


"We're all here because we're not all there" - Guy Favron on Gold Rush

K6 750
rv6john is offline  
post #9 of 20 (permalink) Old 06-27-2019, 02:23 PM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
2006 GSX-R 600 Regulator/Rectifier & Charging Issues

When doing the no load stator test, put the leads across the yellow wires only. You donít put the black lead to ground. As John said, the black lead should be in the COM socket on the meter.

There are 3 stator wires, letís call them 1,2 &3.
Measure AC voltage across:

1&2
1&3
2&3


Iím pretty sure the resistance of the windings should be around 0.2 ohms. Your readings look like the windings are pretty much shorted. Iím guessing you wonít have much voltage when you do the no load test.

Cheers!


Sent from my iPhone using Tapatalk
endoftheline likes this.

Is it June yet?

Last edited by Ozsyd600; 06-27-2019 at 02:28 PM.
Ozsyd600 is offline  
post #10 of 20 (permalink) Old 06-27-2019, 10:29 PM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Quote:
Originally Posted by rv6john View Post
From your picture, you have the scale set right to 200V AC but you have the ground lead in the wrong socket. It should be in the COM socket.

I'm not sure what you mean on your first check to the battery negative. You say voltmeter, but you are measuring resistance.
I mean the yellow wire to ground (in my case, battery negative). Multimeters are referred to as "voltmeters" where I live, hence the confusion. Sorry about that.


Quote:
Originally Posted by Ozsyd600 View Post
When doing the no load stator test, put the leads across the yellow wires only. You donít put the black lead to ground. As John said, the black lead should be in the COM socket on the meter.

There are 3 stator wires, letís call them 1,2 &3.
Measure AC voltage across:

1&2
1&3
2&3


Iím pretty sure the resistance of the windings should be around 0.2 ohms. Your readings look like the windings are pretty much shorted. Iím guessing you wonít have much voltage when you do the no load test.

Cheers!


Sent from my iPhone using Tapatalk
Yep, for the no load stator test I measured the 3 stator wires against each other. I must be an idiot having done the previous tests with the negative test lead not in the COM port, thanks for spotting that

I re-did the tests and got similar low results as posted earlier, 4.5, 4.5 and 4.3. Which are stupidly low. The stator is obviously completely done for.

So now I will be ordering a new stator and gasket and installing it. Will post back once I have an update later next week (have to wait for the parts to arrive).
endoftheline is offline  
post #11 of 20 (permalink) Old 07-07-2019, 01:55 AM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Well...a bit of an update for you all.

I finally had time to disassemble everything after receiving all of the parts.

I can't say I've ever been happy to see a failed component, but at least now I know what the cause of my issue was - a very toasty looking stator coil!

I've replaced the stator and will replace the reg/rec tomorrow, since I had already ordered a new one I may as well replace everything at once.

Thank you to everyone for all of your help. Once everything is back together I'll measure the voltages and fingers crossed will see normal/good results.

endoftheline is offline  
post #12 of 20 (permalink) Old 07-07-2019, 03:44 PM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
Iíd say youíve found the problem!


Sent from my iPhone using Tapatalk
endoftheline likes this.

Is it June yet?
Ozsyd600 is offline  
post #13 of 20 (permalink) Old 07-07-2019, 06:40 PM
Rider
 
PaulPhilly's Avatar
 
Join Date: Jul 2018
Posts: 410
That would deffanitly cause some problems! Good job congrats I bet your itchen to ride again!
endoftheline likes this.
PaulPhilly is offline  
post #14 of 20 (permalink) Old 07-08-2019, 06:09 PM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Yep, everything is back together and I took the bike for a test ride and the charging system is now working as it should.

The only thing I've noticed is that I get a slight whistle noise coming from the stator cover when blipping the throttle at low RPM in neutral/clutch held in.

From the 20 or so forum threads I've read about the whistle noise, it is very common after replacing the stator and not a concern.
endoftheline is offline  
post #15 of 20 (permalink) Old 07-08-2019, 07:39 PM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
Quote:
Originally Posted by endoftheline View Post
Yep, everything is back together and I took the bike for a test ride and the charging system is now working as it should.



The only thing I've noticed is that I get a slight whistle noise coming from the stator cover when blipping the throttle at low RPM in neutral/clutch held in.



From the 20 or so forum threads I've read about the whistle noise, it is very common after replacing the stator and not a concern.


Glad itís working. Did you install OEM stator or ricks Motorsport stator? I had a new whistle with a new OEM stator. I removed the stator and reinstalled it. The whistle went away.


Sent from my iPhone using Tapatalk
endoftheline likes this.

Is it June yet?
Ozsyd600 is offline  
post #16 of 20 (permalink) Old 07-08-2019, 11:17 PM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Quote:
Originally Posted by Ozsyd600 View Post
Glad it’s working. Did you install OEM stator or ricks Motorsport stator? I had a new whistle with a new OEM stator. I removed the stator and reinstalled it. The whistle went away.


Sent from my iPhone using Tapatalk
Replaced both the reg/rec and stator with genuine Suzuki parts.

Not sure if I can be bothered removing everything again and ordering a new gasket, so I might just leave things as is and live with the whistle sound.
endoftheline is offline  
post #17 of 20 (permalink) Old 07-09-2019, 05:04 AM
Lifetime Premium
 
rv6john's Avatar
 
Join Date: Mar 2013
Location: In the twisties around Hendersonville, NC
Posts: 7,989
Quote:
Originally Posted by Ozsyd600 View Post
Glad itís working. Did you install OEM stator or ricks Motorsport stator? I had a new whistle with a new OEM stator. I removed the stator and reinstalled it. The whistle went away.
Interesting. I remember a half a dozen comments a few years ago about whistling stators and I think they were all Ricks. There have been no recent comments so I thought Ricks made some small change.

From your experience, it may be just a slight installation change. Maybe bolted down a thousandth one way or the other.

Quote:
Originally Posted by Chuckster View Post
If you think reading is tricky, how the hell are you going to follow troubleshooting directions?
"Riding well is difficult, riding poorly is easy and painful."
- Nick Ienatsch


"We're all here because we're not all there" - Guy Favron on Gold Rush

K6 750
rv6john is offline  
post #18 of 20 (permalink) Old 07-09-2019, 02:02 PM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
Quote:
Originally Posted by rv6john View Post
Interesting. I remember a half a dozen comments a few years ago about whistling stators and I think they were all Ricks. There have been no recent comments so I thought Ricks made some small change.



From your experience, it may be just a slight installation change. Maybe bolted down a thousandth one way or the other.


I guessed my installation wasnít perfect so just redid it. As I hadnít run the bike more than a few seconds I got away with reusing the gasket :-)



Sent from my iPhone using Tapatalk
endoftheline likes this.

Is it June yet?
Ozsyd600 is offline  
post #19 of 20 (permalink) Old 07-10-2019, 10:42 PM Thread Starter
Squid
 
Join Date: Jun 2019
Posts: 8
Quote:
Originally Posted by Ozsyd600 View Post
I guessed my installation wasnít perfect so just redid it. As I hadnít run the bike more than a few seconds I got away with reusing the gasket :-)



Sent from my iPhone using Tapatalk
When you say not perfect, what do you mean? Incorrect torque settings or something else?
endoftheline is offline  
post #20 of 20 (permalink) Old 07-11-2019, 01:23 AM
Pro Racer
 
Ozsyd600's Avatar
 
Join Date: Aug 2012
Location: Sydney, Australia
Posts: 2,359
Quote:
Originally Posted by endoftheline View Post
When you say not perfect, what do you mean? Incorrect torque settings or something else?


I used correct torque settings - perhaps I didnít tighten them up evenly the first time. Second time I did the screws up evenly in three stages - finger tight, half the torque and then full torque.


Sent from my iPhone using Tapatalk

Is it June yet?
Ozsyd600 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the GSXR.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome