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Gradually gets harder to start and conks out after 8 miles ish

ukjules

ukjules

Forum Sage
I have a massive problem I simply cannot fix.
It may be two.problems.
- the bike after a few runs gets harder and harder to start even though the battery is fine. Cleaning the starter motor sorted it last time but again it's now struggling. Last time I just cleaned it but if thought best I'll order a new brush kit.

The following after I had cleaned the starter motor a few weeks ago - this is happening.
- on a run it simply stopped electrically on a dual carriageway . Showed battery good voltage on my usb attached device but just stopped. Stopped vehicle and tried elec ignition and dead. Waited a bit wriggled a few wires and started again bar labouring a bit due to possible starter motor issue.
So now the bike is totally unreliable I cannot be sure when it will just stop dead.

I attach a picture of the ignition side of the motorbike and can someone tell me if the wiring looks right. I can't do electrics as poor colour vision.

I am very quick with any ideas or tests you want me to do and am armed with all electrical stuff to test.
 

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Update :
Issue 1 (the hard to start)
This is the same as last time which when I cleaned the starter internals it worked fine. I didn't put on a new repair kit / brushes so I assume starter needs this.
(It is.not battery or solenoid or charging !!)
So I'll order a repair kit from ? Or do I just need the brushes from ?

Issue 2 bike cuts out electrically
Will while removing carbs again have a look at wiring bit think I have something wrong.
However bike just run perfectly for 7 miles and IV changed nothing
 
Classic Suzuki charging system failure.
Run the charging tests in the manual.
What output AC per alternator leg at test rpm 5000 iirc

Or test starter by directly connecting to battery with both removed from bike.

The aftermarket ignition is not comforting.
At 127 euros its not likely suited to space travel.
Your reliance on a Chinesium usb volt meter is sub optimal.
 
Charging is not the issue !
charging system fine.

It is:
Starter motor issue . This must be internal as when I cleaned it few weeks ago it solved it.
(I have a thread regarding this )
https://www.thegsresources.com/_forum/threads/starter-motor-dead-gs550e-1980.1787024/

but this must have temporarily sorted the brushes that.must be too worn or something.
It is not battery ,.solenoid or charging system.
I want a new starter motor but alas they don't make em anymore .. impossible to get for my bike !! - have I looked - yes for many years ! I would love to know if they.make.one in china for.mine but they don't seem to. Every other bike but not mine are in eBay.

And probably a separate issue

It cuts out intermittently for no reason.
This is my worry. I just cannot see why.
This.must be a wrong connection or loose or something.
 
Our starter-alternator guy said it was easier & quicker for him to modify brushes he had on the shelf than to try to get them for my nieces Honda 250 4 wheeler. For him it seemed no big deal... No clue about your electrical problem.
 
ukjules said:
Charging is not the issue !
charging system fine.

It is:
Starter motor issue . This must be internal as when I cleaned it few weeks ago it solved it.
(I have a thread regarding this )
https://www.thegsresources.com/_forum/threads/starter-motor-dead-gs550e-1980.1787024/

but this must have temporarily sorted the brushes that.must be too worn or something.
It is not battery ,.solenoid or charging system.
I want a new starter motor but alas they don't make em anymore .. impossible to get for my bike !! - have I looked - yes for many years ! I would love to know if they.make.one in china for.mine but they don't seem to. Every other bike but not mine are in eBay.

And probably a separate issue

It cuts out intermittently for no reason.
This is my worry. I just cannot see why.
This.must be a wrong connection or loose or something.
Click to expand...
Sure its fine......what numbers were produced?
Your electrical wiring is 46 years old. The bodge mods look sketchy. The harness should be checked and cleaned
Any point in the wiring and switches could be corroded to the point of crumbling to verdigris powder.
There are electrical tests for the starter in the fsm. Run them have you? Number?
How are the starter bushings? Slop will cause misalignments binding and an increased load on the system.
 
I may have jumped the gun regarding the overall charging system as I have some odd stats on the regulator of all things

Await update.
 
Update:
- the starter motor is a separate issue. It is on the way out and I need to in some way buy a kit for it. 55£ Wemoto for a kit that gives far too much as only need brushes I think. Before it wouldn't even engage when isolated and 12v to it. A strip down and clean only fixed it for a week until now. Gets more and more sluggish when battery is fine.

Conking out on a run issue:

Battery good
On my usb voltage handlebar thing it shows 13-14v when running up from 12.8 stood.
Yes I can do the rev test later but below some static tests.
I never sighted what voltage displayed when stopped.

Stator test:
Ohms on 3 stator wires , engine off
= 1.2v
3 stator wires to earth = 1 / no reading
(Not done engine started test yet)
But this looks ok for static test....
I have on this replaced the stator a few years ago.

Regulator:
Disconnected regulator from bike / multimeter (mm) on diode test function.

Mm red lead to RR power wire / Mm black to each of 3 RR wires
= 0.14v on all 3 wires (this wrong apparently and should show ol or above 1.5v)

Black mm wire to RR red power wire / Red mm wire to to each of RR wires
= 1 open circuit (should be around 0.5/0.6v)

Black mm wire to neg RR output / Red mm wire to 3 RR wires
= 0.6v
(This should be ol or above 1.5v)

The fourth test I won't go into but it was incorrect as well and showed 1 or open circuit. Should be 0.5/6v

Now I have had regulator problems before and in my notes on paper the one I've just tested is faulty.

What's think ?
Basically it causes the bike to stop intermittently probably eight miles down the road Max. I stop I go again and it will do it again.

What's think ?
I may have an old regulator in stock I can swap out. The one I'm using also is not of the best quality but has lasted many years.
 
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