Help with charging system 1982 Gs850G Melted battery terminal

[Mxzrider98]

Hey guys, So a few months back I got my uncles old GS850 that had been sitting for years. I cleaned the carbs and gas tank and got her running, then went on to replacing other things once I knew she ran. Such as new tires, new air filter, rebuilt all 3 brake calipers, a few new cables, etc,etc.

So here's my problem once I got her road ready and went to go for a ride I discover the bikes not charging. So I think about the spare stator that came with the bike and I go ahead and change it. Still not charging right so after some searching I came across "The Stator Papers" right up here on gs resources and follow the directions there and discover that the stator I just put in is no good either. Next I order a brand new stator, install and come to find out that the R/R is no good. Then I order a brand new Electrosport regulator/rectifier, install and finally I'm getting voltage readings like I should be.

So now I think I'm All set but when i was out for a ride today I stopped at a red light I hear a pop of electronics burning and smoke comes out from under the seat for a few second and the bike died. I push it off the street and pull of the seat and see that the negative battery terminal is melted and so are the ring terminals of the ground wires.

Any ideas of what could have caused this?

[terrylee]

I'm not expert, but was this new battery? I would check the main grounds on the bike, make sure they are clean and making good contact. Actually clean all electrical connections on bike. Also maybe water and acid was very low on battery and got it very, very hot. Another possibility is the r/r quit, some on here have had trouble with that brand of r/r, although not stator. Check to make sure you don't have short somewhere that is making contact with a ground wire, that could create a lot of heat. terrylee

[BassCliff]

Greetings and Salutations!!

Hi Mr. Mxzrider98,

After 30 years all of the electrical connections and grounds have oxidized and corroded. Every electrical connection and ground on the entire bike must be checked, cleaned, repaired, or replaced. This includes, but is not limited to, battery terminals, ground straps, fuse box, bulb sockets, molex connectors, bullet connectors, etc. After replacing the r/r unit you should ground it directly to the negative terminal of the battery. Then check the voltage drop between the r/r output and the positive terminal of the battery. Any voltage drop there means corrosion, extra resistance, which leads to heat, melted wires, blown fuses, etc. Old bike love maintenance. Your "mega-welcome" should help.

If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. In the links below you'll find maintenance lists, documentation, wiring diagrams, "how to" guides, vendor links, tips, tricks, and a whole lot of GS goodness. This is your "mega-welcome". Let's get started.

Let me dump a TON of information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. Now let me roll out the welcome mat for you...



Please Click Here For Your Mega-Welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

More links to helpful threads in the forum:
Help! Your Bike Won't Start
DON'T DO THESE THINGS
Help! Your Bike Won't Run Well
Oh God! Pods!


Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[Guest]

"After 30 years all of the electrical connections and grounds have oxidized and corroded. Every electrical connection and ground on the entire bike must be checked, cleaned, repaired, or replaced."

Not something most people want to hear but it is the cold, hard truth....