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ac genorator or r/r

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My 83 gs 1100 ED is sick! I noticed a wire buning under the seat coming out of the wireing harness. It is green with a white stripe. According to my manual it is one of the wires that links the light switch to the AC genorator? Would this be a problem with the AC genorator, the R/R, or something else? I just got this bike running good after a year of work. Any help would be helpful, as I am completely stumped on this one.
 
Check the Stator Papers (link on the GSR homepage).

My "guess" is that you have a R/R problem. Please check and report back.
 
One of the problems is that the connectors get dirty which creates a resistance that causes heat. (For all bikes) Repair the connections & then check the battery voltages. Most states require headlights on at all times, even if they do not. I ride with it on. It is safe to eliminate the loop thru the light switch. Run the stator wire direct to the reg wire. Leave the light switch wires hang
 
Just went thru a charging problem on my new to me GS1100ED. I cleaned ALL the wire connects, multi pin as well as the single wire connects. I had a very hot r/r and low output to the battery. Only 13.45vts. at 5000rpm even after the wiring cleanup. I made a jumper wire from the b/w wire on the r/r to the neg. battery post. The r/r is now cooler to the touch and has 15vts. plus at 5000rpm. The rubber suspended mounting plate doesn't create a very good ground for the r/r.
 
The Suzuki Factory Service, STD charging output, calls for 14-15.5V(DC) at 5000RPM. On pg.33 of the GS1100E supplement. Mine is 15.2V at 5000RPM. Also on pg. 33, the STD No-load performance for the AC generator is 80V(AC) or Over at 5000RPM. I would not post this unless I had the Official Manual in front of me.
 
rustybronco said:
15 VOLTS + is to high of a charge voltage.
Click to expand...

Rusty is right. It is too high, but I wouldnt sweat it. Keep checking the battery level and it should last at least 3 seasons. Mine runs over 15vdc and I top off the battery a couple times a season.
 
The manual is wrong?? The manual covers models from '80 1100's to '82 1100's. It shows the same specs for all. It seems sorta high to me too. A 550 Kaw I owned would boil the water from the battery. Then I changed the rear turn lamps into running lights and T signals. The extra wattage slowed the water loss.
 
My r/r ws going out when mine was putting out that much voltage.I had to add water to the battery every 250 miles or so.Check your r/r.
 
GS550 manual states 14 - 15.5v @ 5000 rpm.

Stator papers lists 14.5v so I'm not sure what's going on either. I think I'd leave well enough alone...or you can pick up a late model R/R off ebay for cheap. I picked up one from a 2004 Honda CBR600 for $27 shipped. Going to play around with it and compare to my stocker(s). Can't hurt to have a spare around. :)
 
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