1980 GS850L charging system woes

[posplayr]

Steve, the used 1982 GS1100G stator cost me 2500 of my pinched pennies which included free shipping. The used Polaris rectifier/regulator added another 3749 of my pinched/scrimped together and saved pennies. I had spent $5.00 on the 17 gauge high temperature magnet wire previously and never mind how much (minivan fuel hog) gas to drive about 40 miles round trip to pick it up. The Glyptal was about $7. I also have spent another $14 for these little gems :

http://www.ebay.com/itm/Regulator-R...ash=item43d8fb6415:g:yVoAAOSwNSxU~yBm&vxp=mtr

and another $47.89 for what is touted as a "high output stator", a new one that says it is an exact fit for my GS850L. The last two items are scheduled to arrive in the mail, tomorrow. I still may get in a bit of warm weather holiday time on my Little Suzy.

If it wasn't for this forum I'd probably still be trying to wind the stator yet again !!! Who says I've smartened up ?

Make sure the R/R says SH775 on it to make sure it is genuine. Follow the wiring directions in GS Charging health and you should have no further problems with this.

As mentioned earlier a little solder in the crimps will bond them to the wire precluding corrosion from getting in. Some Deoxit spray applied will help as well. As it removes corrosion and treats the metal protecting against corrosion. This is especially important for anything connected to the R/R and any current paths between the R/R and the battery.

 

[Steve]

Make sure the R/R says SH775 on it to make sure it is genuine. ...

Very true. I have noticed some very careful wording on some of the listings that say "Repaces part # such and such". That does not mean that it's the same part number, just that you can replace it with this one.

For those looking at used offerings on eBay, don't drop any coin on the auction unless you see the "SH775" picture.

.

 

[Brendan W]

Very true. I have noticed some very careful wording on some of the listings that say "Repaces part # such and such". That does not mean that it's the same part number, just that you can replace it with this one.

For those looking at used offerings on eBay, don't drop any coin on the auction unless you see the "SH775" picture.

.

True that. The tell is usually phrases like 'replacement for' and 'with thermal protection'. Digging deeper they appear to be MOSFET shunt units.

 

[850 Combat]

I've put a lot of Honda regulators in GS bikes. 2 850Gs, 3 1000Gs, and an 1100G. Never a problem, and dirt cheap. Get one off E Bay from a GL1000 or GL500 Honda. 20 bucks. I have some spares, but I'm nowhere near my home. I want to upgrade to the Polaris type, but the Honda units have been absolutely NO PROBLEM.

 

[tirebiter]

Make sure the R/R says SH775 on it to make sure it is genuine.

This is what I have:



Hope it's the right one

 

[posplayr]

This is what I have:

View attachment 45770

Hope it's the right one

Looks like a real one

 

[tirebiter]

Seems to be working like a real one. Stator is hanging in so far after 80 miles, today.

I have a crimping tool "AMP SERVICE TOOL II":



I thought somebody else may have a need to see the difference in stator size :

 

[tirebiter]

So here are a couple of photographs of the burnt stator from Little Suzy and the wrong one I bought from eBay for $25.00:

 

[tirebiter]

this view shows the difference in size more clearly :

 

[Grimly]

So here are a couple of photographs of the burnt stator from Little Suzy and the wrong one I bought from eBay for $25.00:

View attachment 45783

Yep. I did that, too. Following a badly-worded and laid-out x-ref on the original Stator Papers, which apparently said the GS1100 stators were the same as the others. Only a couple of them are, but the larger ones lie in wait for the unwary.

 

[tirebiter]

Yep. I did that, too. Following a badly-worded and laid-out x-ref on the original Stator Papers, which apparently said the GS1100 stators were the same as the others. Only a couple of them are, but the larger ones lie in wait for the unwary.

I didn't even realize there was a cross-reference listed on the stator pages ! I guess I should have looked more closely. Instead I utilized the parts fitment feature on many of the parts suppliers web catalogs to try to make sense of it.

Trouble is, on those catalog pages/micro-fiche the generator is listed as one part number for the stator and rotor together. The part numbers do not always match up though.

For instance on Babbits, my bike calls for a 31401-45120 generator assembly/stator/rotor. The same P/N also fits only a 1983 GS750S. No other bikes listed. When I go to the 1983GS750S page it shows the same P/N but then it does not include ANY other bikes that the generator assembly fits.

I tried to make sense of it and failed with my single attempt at getting a used one from a larger displacement GS. I had always thought the lower end on my 850 was the same as the 1000 and 1100 bikes but I guess not. I read somewhere in these forum pages where there were two different sizes listed so I was aware at least. Just not as fully informed as I needed to be.

Does anyone know all of the cross references for all the GS stators out there ? I was amazed at how many variants there are all from the same core, never mind adding in a larger core which makes things even more complicated. I Assume Suzuki had trouble deciding which scheme to use in the charging system and so made several different attempts.

And now comes along PosPlayer who it seems, has introduced the motorcycling world to the series style rectifier/regulator to settle it all, maybe for all time. At least for those of us who are more interested in driving these bikes constantly and will probably be adding or deleting electrical equipment as deemed necessary ... and less interested in keeping them as original. So far, my Little Suzy is very happy with the new stator that has 18 gauge wire but apparently less windings than stock (touted as high output) and series R/R.

The question remains in my mind at least, How many amps can this charging system safely develop at 12 Volts ? There is no mention in the Factory Service Manual. Now with the series R/R and this supposedly "high output" stator , I assume that might be a different number.

For the record, I ran the stator wires directly to the RR, deleting the handlebar loop. I used 10 gauge wire on the positive and negative wires from the RR. Positive is soldered to the red lead that the original RR was attached to. I also incorporated a single point ground but after looking at other schemes for this I need to put in a larger capacity wire from the SPG to the frame.

I still have not added an relays but I am definitely wanting to take the ignition switch contacts out of the loop that powers all the lights, coils and horns. Just to hopefully make the switch last longer.

 

[posplayr]

you should confirm your installation using the Quick test and then the Revised Phase a test results.
You won't get any more power from the charging system other than about 50-70 watts unless you start removing loads like the headlamp and tail lights and switch to LED. This could add another 60-75 watts easily

 

[Grimly]

Does anyone know all of the cross references for all the GS stators out there ? I was amazed at how many variants there are all from the same core, never mind adding in a larger core which makes things even more complicated..

I was using the Electrosport model numbers and x-reffing them on their site, and discovered that the GS850 18-pole stator is apparently the same as the GS500 - from that, other sources seemed to confirm it. Recently, BWRinger mentioned he'd been using a GS500 stator on his 850 happily enough. I suspect the 500 stator is thinner, so might not be able to satisfy the same peak demand as the 850 item, but in these days of LED headlamps, that's not such a big deal. There might only be a couple of amps in it, anyway.
Somebody drew up a list on here a couple of weeks ago, which was reasonably comprehensive.
Cheap stators from China to fit the GS500 are being shipped for as little as 20 bucks to your door - but caveat emptor. At that price, it's worth taking a gamble and if it lasts, it's great. If it doesn't, well... <shrug>.

 

[tirebiter]

You won't get any more power from the charging system other than about 50-70 watts

I take it that would be in the range of 4 -6 Amps at 12 Volts.

I added up the Watts used just by the light bulbs according the the Factory Service Manual. Anywhere from about 63W running with low beam to about 91W with high beam and brake lights on. Horns and turn signals would add more load, at times.

I don't know how much the coils take but at only 4 ohms resistance, I imagine it's up there. Additionally the ignitor uses some juice, also.

Recharging the battery after starting the engine would take more, for a short while at least.

Maybe I asked the wrong question. I'll try again. Does anybody know the maximum amount of Amperage (at 12 volts) the stock GS850GL stator is rated for ?

 

[posplayr]

FYI Suzuki only lists the light loads although it is easy to measure the r/r outputs 14-15 amps at 14.5v with standard loads. You can put additional loads on as indicated without impacting the 14.5v . I have never done this but several people report using heated gear.

And btw, the stator is not the limiting factor so it will not have a current rating; it is the magnetic rotor.

i don't know how much load you can put on before you draw the voltage down to 12v. Perhaps double what I indicated.

 

[tirebiter]

Just an update. Have not had a chance to do a thorough evaluation as per the "charging system health" procedure as yet. It will happen soon ... I hope. Need to make time for it as I am sure I will uncover something that should be easily taken care of now before it causes any problems down the road.

One thing I should mention. I double checked regulator ground wire. I put it on the battery terminal, not at the single point ground location as previously reported.

For now the turn signal flasher speed indicates everything is still ok with about 400 miles on the new stator and used series regulator.