Bad Stator - confirm?

[allojohn]

Well gentlemen that fixed it. I'll do the Posplayr "Quick check" this weekend and post the results but once I'd fixed the ignition connector I got 14+ volts with the headlamp on - that's never happened before.

So it wasn't the stator at all..........

[allojohn]

The Hitachi connector from the ignition seems to be the culprit. It's a little melted and disintegrated when I pulled it apart. Some of the wires were fused together. Boy, I hope this fixes things.......

[allojohn]

Thanks for that Normk but I am getting somewhere with this.

I measured the voltage with the lesser bulb attached, on and hanging from the connector and got a reasonable charge at 13.7. So I put the headlamp back together and guess what, the charge went back to 12.30. Took headlamp off and up went the charge.

I then wiggled the wiring in the headlamp and the voltmeter went crazy - from 11.** to 13.** and every number in between. Methinks I have a short!

PS All meter readings are across the battery.

Haven't read the complete thread but wondering if your alternator output is simply not sufficient for the added headlight load?

My old GS850G has only about a 20 amp total output so using a high output headlight bulb such as a 90/100 Watt would challenge the system's ability to maintain voltage. You mentioned aftermarket (ignition) coils which may also draw more than stock.

An common issue with motorcycle voltmeters is that they are often wire into the harness and so do not monitor the charging voltage but rather "see" the voltage following the quite large voltage drop inherent in most bike wiring due to the tiny wires used.

I've often measured over 2 volts drop between battery/VRR output and the headlight. Are you measuring voltage with a hand held voltmeter and across the battery?

Don't like to muddy the water when others are working on the problem but looked like there may be test result issues.

[allojohn]

Update...

Changed the bulb for a regular old Sylvania 9003 HB2/HB4, now I get 13.70V at 2,500 rpm. That's a damn sight better but is it acceptable?

[allojohn]

When I was young, I wanted more lighting out of a 6 volt magneto system, so I rewired and I had both hi and low filaments come on in hi switch spot - worked great for 5 minutes and I had exciting ride home with no headlight.

LOL, I read a mod on this forum to do exactly that! I don't think they gave an estimate of battery life though.

[tom203]

When I was young, I wanted more lighting out of a 6 volt magneto system, so I rewired and I had both hi and low filaments come on in hi switch spot - worked great for 5 minutes and I had exciting ride home with no headlight.

[allojohn]

seems like you might be trying to power both at the same time

White wire is LO
Yellow wire is Hi
both should not be on at the same time.

No no, I've got hi/low using the switch. They're not on together.

But the headlamp is the problem. Now I've just got to figure out why.

[posplayr]

No, I've got hi/low. It is pretty bright though.

seems like you might be trying to power both at the same time

White wire is LO
Yellow wire is Hi
both should not be on at the same time.

[allojohn]

Must be some bulb- you sure both filaments aren't going on together?

No, I've got hi/low. It is pretty bright though.

[allojohn]

This guy did the same and has the same problem. Strange?

http://www.thegsresources.com/_forum...32&postcount=2

Bless us! Do you think the headlamp relay mod would help?

[tom203]

Must be some bulb- you sure both filaments aren't going on together?

[posplayr]

Sir, you are obviously unaware of my electrical shortcomings!

Update......

Headlamp OFF
Key off 12.80
Key on 12.30
Idle 12.70
2,500 rpm 14.30
5,000 rpm 14.40
Key off 12.80

Headlamp ON
Key off 12.70
Key on 12.00
Idle 12.15
2,500 rpm 12.43
5,000 rpm 12.50
Key off 12.32

One last thing I haven't shared with you is I replaced the headlamp with a Silverlight H4 (Bosch) conversion. I ditched the original some time ago and wish I hadn't now!

This guy did the same and has the same problem. Strange?

http://www.thegsresources.com/_forum/showpost.php?p=1662632&postcount=2

[allojohn]

I cant imagine you could have done anything without smoking and cause this.....

Sir, you are obviously unaware of my electrical shortcomings!

Update......

Headlamp OFF
Key off 12.80
Key on 12.30
Idle 12.70
2,500 rpm 14.30
5,000 rpm 14.40
Key off 12.80

Headlamp ON
Key off 12.70
Key on 12.00
Idle 12.15
2,500 rpm 12.43
5,000 rpm 12.50
Key off 12.32

One last thing I haven't shared with you is I replaced the headlamp with a Silverlight H4 (Bosch) conversion. I ditched the original some time ago and wish I hadn't now!

[posplayr]

Good question, actually I'm not sure.

I replaced the stator (Electrosport) and did the quick test.

Headlamp OFF
Key off 12.51
Key on 12.06
Idle 12.60
2,500 rpm 14.30
5,000 rpm 14.30
Key off 12.90

Headlamp ON
Key off 12.65
Key on 11.90
Idle 12.20
2,500 rpm 12.60

Got called away and didn't complete.

I'm beginning to think I've screwed some wiring after doing relay mods on the coils & Dyna ignition and the horn.

there was another guy having very similar symptoms......

I cant imagine you could have done anything without smoking and cause this.....