Bogging down gsx250e after a mile always and stops

[Rob S.]

I cannot push that bike again for a long long time.

I was 57 and a mile from home when my 11E snapped the chain. It was mostly uphill, but the push home was quality alone time with Suzi.

A 250? A stroll in the park.

[grcamna2]

Subscribed this is a great thread.

[Gorminrider]

Yay! That wasn't so bad was it? .. easier than your trouble with the signal generators? and now you have a new clutch cable and R/R as well!

[ukjules]

Conclusion:

The final issue was indeed that mad design of a plate that holds RR, igniter and Solenoid with no secure earth.

Bike runs reliably now with working RR and running wire earthing plate to bike frame.

[ukjules]

You got it !!! It is a mad design and I'm so glad
you noticed it.
I dare not run bike to shops (16m round trip) yet but will run 1m from home
in circuits for a while.

I cannot push that bike again for a long long time. The bike cracked me so many times but this has to be a fix.
It's logically what happened.

[Gorminrider]

Yes, that's a problem that might be peculiar to twins*. The ground on that plate that seems to be otherwise only attached to the airbox through insulating grommets. I don't know how they even ran out of the factory. What with fitting in new regulators and such I've lost the plot of whatever magic they were using so I ran a ground to the frame myself...

and, note-too-self, I mean to move the ill-fitting replacement R/R to the bottom of the battery box or elsewhere someday

[ukjules]

argh. I'll run a wire from plate to a good earth
that done ... again OK.
I'll test 1m around home as cannot ever have this issue 10mipes out again.

stator test with all working - 75vac on all combinations.

surely this must be a fix !!!

[ukjules]

Update:

Started too look at the plate that the RR, Solenoid and igniter etc sits on. It is also the earth to these items and rear lights indicators.

So re checked wires , cleaned , renewed some but noted the entire plate is only earthed to bodywork via a rusty / dirty tab. See picture.

This is clearly a bad earth possibility and a hopeless design.

So I have cleaned the tab and again it will stop but won't if I hold the tab firm to the bodywork.
So now I xan always start it if I hold the tab to the bodywork.

How on earth do I redesign that tab to work as an earth ?

[ukjules]

Update:

This morning battery 12.7v. thus it should start bike. ignition only nothing else works.

- if I bridge solenoid terminals starts immediately no probs at all. As soon as I take of connection stops dead.

So this is a electrical issue ? What could cause that as there is no reason it should just stop ?

[ukjules]

I'll do some tests on stator and coils tomorrow.

It simply cannot be the RR or the Battery.
I can put them both on GS and it would
work perfectly.

[Cipher]

My 550 spec is 75 VAC at 5000 rpm. Stator test is easy to do. Measure each leg and check to assure there's no shorting to ground.
An El cheapo voltmeter that you can monitor while riding would be helpful.

your description is classic gs undercharging.
oddly in spite of three oem reg/rect failures my stator works perfectly.
my compufire unit works perfectly.

[ukjules]

It is my new battery from.my gs550e. it was
in perfect condition.
Now off and tests at 12.7v So this time
the zero elecs bar ignition lights is not
the battery. it can't be RR either.

I think we can assume this issue was hiding behind the prev RR issue now fixed.

(the old gsx battery that had been on during this debacle, is now on my gs and is restored! zero issues. iv done 2 100m trips on it)

I can test stator tomorrow ?
and prob coils. you guys want that analysis ?

I just can't see what else it can be ?
I can now never ride this again in fear of this type of breakdown so all tests must be near my house.

I was saved today amazingly by a chal in white van who stopped put bike on back and lift back to my house .

[Cipher]

Multiple short trips at an average insufficient rpm result in depleted batteries.
is it the battery you've used all along? If so its very likely cooked.

[ukjules]

UPDATE:

It has happened again !!!
Good battery
Seemingly good RR off my GS550E which worked fine.
Been OK for a few 15 miler rides.

Can get about a few miles now then dead no elec bar ignition light. no horn , lights or start. I leave say 5 mins then can go a mile again ?

This has totally got me now ? What on earth do I test now ?

I'll immediately swap batter and rr back to 550 and make sure they are fine.

Help !!!!

[ukjules]

Conclusion :
gsx250e- it was the regulator. swapped and re jigged my gs550 RR and been fine ever since.

I am yet to buy the mega RR I linked of the right type but if my 550 one fails I will.

GS550E- on this I have my old sense wire RR, Which for some reason I took off (as suspected this many years ago)
Anyway old gsx battery (which the gsx RR almost destroyed) and that old Sense wire RR , and ride to Fairford air show and back and all good.

All I can say how a faulty RR reveals itself sends you on a merry go round of possible fixes. I had the carbs off many times and bench tests on the RR basically said it was OK!!!!!!
clearly I assume it was not OK when it got hot (which it did , very ).
Thanks all.