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still suffering charging issues/complications

  • Thread starter Thread starter paulie
  • Start date Start date
P

paulie

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Hi, Paul here again. It's been a while since I've posted, and as most 19 year olds, college/work have been slowly taking my life away. Anyways, springs here and it's time to ride. Last time I posted I was having charging problems, so last weekend I tore into Samantha (1985 GS550L) and I tested my rectifier as well as my stator. Stator tested/looked good, rectifier not so much (4 connectors/ harness slightly burnt and melted as well as not consistent). I ordered an Electrosport R/R and it was all plug and play from there. Turned the key, primed the bike, cranked and fired for about a millisecond and then poof. All electronics gone. After a moment of silence and saying about every word in the book, looked at my fuse box, and saw a 15AMP fuse for my main power slot blown. "Okay", I thought, "New fuse." Plugged a fresh one in and same thing. Crank, millisecond fire, dead. After, unplugged the R/R, bike started up fine and ran. I'm honestly stumped. I searched for shorts, none of which I could find, and slowly started plugging in the R/R as the bike was running. Last wire I plugged in blew the fuse again. Tried many different combinations and if my mind serves me correctly, its always the last wire to go in that blows the fuse. Any ideas? Maybe a slightly bigger fuse? Perhaps a faulty rectifier or not using the correct size fuse? Please help me save Samantha. :(

-Paulie
 
paulie said:
so the 4 wires have to be connected to a specific connector?
Click to expand...

Sounds like the R/R has a short. Did you wire it in backwards ??? Double check that the red wire is going to hot and the back to ground.

If not try and do the Phase B C tests that check the diodes. There is a short somewhere and it is probably in the R/R or the connections you are making to it.
 
I wired it in exactly the way it was last time, plugged 4 red connectors, then single connector to the wire leading to the fuse bike. That's weird though, I see all these posts praising "ELECTROSPORT" and I guess maybe it would be my luck to get a dud lol.
 
And also, I'm sorry if I don't understand a step or what to do at certain points. I'm a visual learner lol
 
mine had a spade looking head on the single wire, no ring. had to switch it out to fit the fuse box. thats how it was last time
 
I'll show you guys a picture of the way everything is plugged in tomorrow and how it looks, it's too dark out now and raining. No lights in the storage unit :(
 
alright, thanks for the speedy responses guys :) I'll be back tomorrow after work.
 
alrighty, back from work and went to see Samantha. Let her run for a few and took some pictures of the wiring.
 
this is the single wire that attaches into the single wire of the rectifier on the end. also attaches to fuse box, I'll post that as well
 
both wires attached to rectifier, had to change head of single wire due to connector not matching up.
 
all 3 wires from stator plugged in as well. I did check the stator, looks fine, coils don't look burnt/broken. Would pulling the clutch cover when trying to gain access to the stator maybe have throw something off?
 
alright, I'll stop loading up the feed now. last and final picture, i traced the wire back to the fuse box which also leads to one of the 4 connectors. YELLOW head behind duct taped front one on right side bottom of the fuse box (blue 15 keeps blowing btw). All in all, I'm not entirely sure what the last owner/mechanic did with the wiring, so if you guys see a possible flaw or a big "no-no" in terms of wiring, let me know. If you need more detailed pictures or pictures of different areas of wiring, I will be happy to fetch them for you :)
 
Hard to tell what's going on there but charging system 101 class teaches to do the following:

1) Wire the stator wires directly into the R/R. Bypass the existing harness completely.

2) Connect R/R positive output to fuse block. Clean the connector terminals to reduce voltage drop.

3) Make sure your R/R is solidly grounded. Use a jumper if needed to make sure.

Please confirm the following and then report back...
 
Last edited:
okay I'll check! 2 questions though, when you say bypass the harness, what about the 4th plug on the rectifier? just plug the three stator wires into any three random rectifier plugs? (inside of the white plastic housing) and also, ground out the rectifier how? I'm still new to this, please keep the flogging down to a minimum :( lol.
 
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