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GSXR 600 K1 low charging

157 Views 8 Replies 4 Participants Last post by  MadisonMotorsportUK, 
mactenn
Hi, coming in with the CLASSIC GSXR problem, not charging properly. Not my first rodeo with charging issues, but this time I can't seem to find the solution. And I want to make sure I have checked every option before going for the stator switch (I hate this job).

Background info:
  • GSXR 600 (2001)
  • Stator replaced in 2020 summer
  • Brand new battery

Problem:
  • With fully charged battery, when on idle, voltage measured on battery terminals is 12.8V
  • When headlight is on, battery voltage drops and keeps draining, even when revving around 5000rpm
  • When headlight is off, it's actually charging battery a little, voltage gradually climbs over 13.5V. When revving 5000rpm, it climbs faster.

What I've done so far:
  • Current leakage test: 0.8/0.9 mA
  • Generator coil resistance: All wires read 0.6Ω output.
  • Generator no-load performance: 2x over ~70V; 1x ~65V
  • Regulator/Rectifier test: All diodes are within the value given in manual (~0.5V and ~0.9 on BR-BW connection)
  • Cleaned and re soldered stator connections and R/R connections (plugs have been melted previously and I had the connections directly connected)
  • Cleaned terminals connecting battery
  • I have also measured voltage on stator - R/R connection, where voltage measures ~10V and then right after R/R on the R/R - Battery connection where it acts like on battery terminals, but about 0.5V higher.
  • I also tried with switching original R/R to Aliexpress R/R (which failed diode test tho), but it gave basically same outcome

Any ideas, what else should I check? I also found here, someone had similar symptoms, and the issue was flywheel, but in my case, if it reads correct values on no load test, I'm not so sure.
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A
Can you please rephrase this part?
I have also measured voltage on stator - R/R connection, where voltage measures ~10V and then right after R/R on the R/R - Battery connection where it acts like on battery terminals, but about 0.5V higher.
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mactenn
Basically I did no load test, but with plugged wires to R/R and when I measured on connection terminals I got around 10V going in R/R and around 12.5V going out of R/R (measured on BW-BR wires). No idea, if it is useful information or not, but at this point I was checking everything.
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A
Is this done with the R/R output disconnected? If not, can you measure again (both inputs AC and output DC) with the bike running?
My best guess is there's a short on the wiring harness, between RR out to battery.

Something is clearly overloading the system to cause the stator AC dropping to 10V, while measuring ~70V AC when disconnected.
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Ozsyd600
When you replaced the stator in 2020, did you use an OEM gasket?

Did you use any RTV or other sealant?

What does your multimeter show as resistance if you just connect the meter leads together?

Did you measure resistance of each stator wire to a good ground point on the bike?
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mactenn
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Ozsyd600 said:
When you replaced the stator in 2020, did you use an OEM gasket?

Did you use any RTV or other sealant?

What does your multimeter show as resistance if you just connect the meter leads together?

Did you measure resistance of each stator wire to a good ground point on the bike?
Click to expand...
I used gasket from ebay and also used RTV silicone to seal cover.

When connecting multimeter leads, it reads 0.1Ω

Resistance for each stator line to ground is 0.8Ω

alexei said:
Is this done with the R/R output disconnected? If not, can you measure again (both inputs AC and output DC) with the bike running?
My best guess is there's a short on the wiring harness, between RR out to battery.

Something is clearly overloading the system to cause the stator AC dropping to 10V, while measuring ~70V AC when disconnected.
Click to expand...
Alright, so I measured again, and DC output at 5000rpm was ~1.5V, while AC input was 2.5 - 3V (I either remembered 10V wrongly or number has just dropped even more)
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Ozsyd600
You need to test the stator AC voltage with the r/r unplugged with the bike running at around 5k rpm.

With the winding resistance test, you need to subtract that 0.1ohm from your reading to take the meter internal resistance into account.
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mactenn said:
Resistance for each stator line to ground is 0.8Ω
Click to expand...
If this were measured with the 3 wires disconnected from the R/R, the stator is toast.
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MadisonMotorsportUK
Stator. Apart from anything else, you have one phase outputting 10% less voltage. I'd replace the reg/rec as well for belts and braces - not a cheap Chinesium one, OEM/Ricks or do an R6 conversion.
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