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New Stator and R/R, low voltage output

  • Thread starter Thread starter theitalian
  • Start date Start date
T

theitalian

Guest
I just bought a 1980 gs550E and realized it had the famous charging issues. Voltage from the stator was low (0.2 at idle to 1 volt at 4000 rpm) even though previous owner said it was new. I replaced the stator, r/r, and battery with new units. The stator and r/r are electrosport units. Output of stator is still low, same as before, along with the output of the r/r. Not sure what to do next. Could it be the flywheel? Anyone have any ideas? Thanks!!
 
First the stator voltage is measured in AC voltage !! So disconnect the stator and recheck using the AC scale on your meter.. Also check from the + battery to the red on the regulator should be less than .5 volts DC, higher reading means bad connections somewhere in the circuit
 
First, Welcome to GSR.

Similar to what Lynn says:

- are you measuring the stator voltage with stator disconnected, engine at mid rpms (like you said), and meter on AC scale .... ?
Measure from stator wire to other stator wire, 3 different combinations.

- Also, with everything connected, and engine at mid rpms: measure from R/R output (Red wire) to battery positive, should be about zero point zero DC volts. ... And also measure from R/R negitive (Black wire connected to battery box usally sonoid moiounting bolt) and the battery negitive, should be about zero point zero DC volts.

Tell us more what you find.

You are correct that if the rotor on end of crank were to loose its magnitism that the charging system would not work.
But that would not be a likley suspect compared to all the other possible causes that happen so often.

Good that you have a meter.


Hawaii !
Dont recall any previous member from Hawaii.

.
 
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Rockford is in Hawaii. Another note: make sure all the ground connections are good.
 
Thanks for the warm welcome!! I love the site and appreciate all the help.

Hawaii is nice but finding parts/good deals can be tricky :).

After reading all the guides and forum posts, my first assumption was the stator. I tested the original (new from previous owner). Used a multimeter on AC and measured between each leg of the stator (A to B, B to C, A to C). This was done with the stator isolated from the rest of the system. Came up with 0.2 to 1 V from idle to about 4000 rpm.

Assuming the stator was shot, I replaced it, repeated the tests, and came up with very similar results. I thought the multimeter may be acting up or not capable of handling the various AC frequencies, so I replaced the r/r. The output of the r/r is slightly higher, about 0.2 to 2 V (DC) from idle to 4000 rpm. It seems like everything is working, just that the stator is not producing enough power.

I haven't cleaned any connections or tested any other voltage drops through the system yet because I figured I was measuring the stator directly and these would not affect it. Is this a good assumption? I plan to clean them once I get this sorted out.

If the stator is ok but not producing enough power, I figure it could only mean:
1. the flywheel isn't spinning as fast as the engine (not likely)
2. the flywheel isn't surrounding the stator completely for some odd reason
3. the magnets are shot (broken or have switched polarity)

Thinking of replacing the flywheel next. Any ideas? Thanks for all the help!!
 
Greetings and Salutations!!

Greetings and Salutations!!

Hi Mr. theitalian,

Are you sure it's an '80 model and not a '79? If I recall, the '79 uses a 12 pole stator and the '80 uses an 18 pole stator. The stator pole count has to match the number of magnets in the rotor (actually, must be a proper multiple) or it will not produce AC. The stator should not be grounded to anything.

Anyway, let me dump a TON of information on you and share some GS lovin'. :D

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


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!"....
hat1.gif


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...

carpet.jpg


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! :D

Thanks for joining us. Keep us informed. I will put you on my prayer list.

Thank you for your indulgence,

BassCliff
 
BassCliff said:
Hi Mr. theitalian,

Are you sure it's an '80 model and not a '79? If I recall, the '79 uses a 12 pole stator and the '80 uses an 18 pole stator. The stator pole count has to match the number of magnets in the rotor (actually, must be a proper multiple) or it will not produce AC. The stator should not be grounded to anything.


BassCliff
Click to expand...
Good point! easy to get wrong one but................ these voltage readings are way low. Best to double check multimeter ( measure battery, and then ac house voltage ) to check meter and operator. Weak magnetism would be unlikely
 
Last edited:
TheItalian,remote possibilty...electrosport stator is wrong size,maybe # of poles or overall total physical size ,it may have bolted in ok etc. but you must find OEM Suzuki stator measurements,meaning Dia and Width across pole tops then check/compare against what is in there now.If what was in there is same size as what you took out ,you may have thought all is fine,if it matches,but they might both be wrong(physical size).Smaller Dia=incorrect air gap to spinning magnets and narrow pole width less coil windings resulting in low voltage.This happened to me on my 550.Electrosport stator was:102mmx19mm vs 105mmx30mm(OEM Suzuki and Ricks).I believed was doing everything proper too: getting no results.Make these Physical Size stator measuements just so you know this much is correct.
 
Last edited:
Just checked on Electrosport's website. These are the parts and part numbers recommended for Suzuki gs550 77-80, 8 valve. Are they the same as yours?


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Thanks for the epic welcome BassCliff!! Been admiring your tutorials and putting them to use. I appreciate all the time you've put into them and all the help you've given. That goes for everyone on here, thanks for all the help!!

I've had an amazingly difficult time finding info for a 1980 gs550E stator. I believe they are 12 pole stators but I can't be certain. It seems that the 18 pole stators were used on the larger engines. I have the manual for the bike and I'll have to double check it. That's also assuming the flywheel is stock and hasn't been replaced with one to work with 18 pole stators. I'll have to check both the manual and bike when I'm working on it next.

Thanks Tom, I had the same doubts and checked the AC measurement against a wall outlet. I also used two different DMM just to be certain.

That's an interesting idea about the stator not being the right size. I'll have to look into what the dimensions are for the original. Although the previous stator (new from previous owner whom I trust) is supposedly an OEM stator and it performed similar to the new electrosport stator. I'll measure both stators and flywheel when I open up the bike next.

Yup, the items listed by bccap are the same items I purchased. I appreciate you taking the time and effort to look into it yourself. I couldn't find a definite mention of 1980 gs550E, just 1980 gs550 8 valve. From what I can tell, this covers my bike. I emailed electrosport before the purchase and double checked the description online and made sure the 12 pole was the one I needed.

Thanks for all the help!
 
Rick's Motorsport Electrics.com OEM style Suzuki 1980 Gs550E Product#(21-3010),Website page picture' appears" to be !8 pole stator,I do not make any claims.
 
Interesting, I may buy an 18 pole to try out when I take it apart next. Thanks!
 
Fixed it!!!
Thanks for all the help, couldn't have done it without you guys.
It was the stator. BassCliff you were correct with your original idea, it needed an 18 pole stator. Electrosport lists the wrong stator. Thanks to elrico and BigD for helping me find the appropriate item and thanks to everyone else for taking the time, I appreciate it!! I ended up with an rmstator product, switched it this morning, did some wiring, and now have a fully operational bike.
 
Hi,

It's great to hear that another classic motorcycle is still on the road. Good show!


Thank you for your indulgence,

BassCliff
 
I thank You, for good news report.Am in Hi Feb,will keep look out for sweet GS with bright headlight.What is color of paint,if you don't mind?
 
haha excellent, its red
hope you have a good trip!! feel free to ask if you have any questions
 
theitalian said:
haha excellent, its red
hope you have a good trip!! feel free to ask if you have any questions
Click to expand...
With a handle like yours, I hope you chose Ferrari Red. Post some pics soon!

I'm glad my mad observation skills helped out.
 
'That's Amore'.. " Dino " Martin sing .. Suzuki homage to Italy/Red:1996 Bandit600S,Colour,"Italian Marble Red". their version. Pizza Pie Tonight!
 
aint it the truth. if i hadnt happened across this site, it would be like groping around in the dark. 7 mo into my project and i took it for a ride today. dont think i would have, if it wasnt for all these members helping out.
 
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