I'm having issues...

[Pancakes]

Does your battery get crystally build-up on either (or both) terminals?

[Winter]

Does your battery get crystally build-up on either (or both) terminals?

There was a little bit, but not an excessive amount, on the positive term i believe.

I've cleaned all that off now anyhow.

[surfer]

These dudes have given you a great place to start; the battery. With the battery in the bike and connected check the current across it with a multimeter. See Davereids comments for amount of volts.

If the battery fluid level is low top it up with distilled water. If the volt level of the battery is low charge it overnight on a trickle charge.

Then when you have proved that the battery is ok see Daverieds comments on where to start next.

If it is the battery and your battery is not holding a charge then you will need a new one. Sometimes you can spot a damged cell because it will look different to the other cells when you view the battery from the side.

Sounds like your bike has been running on the battery and the charging circuit is faulty. You should have about 12 to 13 volts on the battery when the bke is not running, and 13.8-14.5 when the bike is running at about 2000-3000 rpm. Lower than this means shes not charging. Reasons for not charging, assuming all connections tight :

1. Faulty battery
2. Faulty regulator
3. Faulty rectifier (often in the same box as the regulator)
4. Faulty stator
5. Faulty rotor (no magnetisim left - very uncommon)

Hi

Start with the battery, determine whether it is in good order as it may indicate another problem.
If the battery is stuffed the voltage will be erratic and all kinds of chaos will happen.
You may well have a charging issue though if the battery is good - get it sorted pronto or the problem could cost more to sort.
If it's the reg/rect you may be able to get a 2nd hand one as many small Suzuki's use a common one (RGV250 is one)

No one likes being stranded.

BB

[Winter]

thanks for your help so far guys.

I've discovered its an intermitant fault, and have found if i yank on a certain part of the wiring it will stop for a bit.

So now i just need to find somewhere there is a break.

[Winter]

Problem solved!

I dismantled the bike (fairings, tank etc), removed all the wiring, deloomed it all - that was some stiiicky crap, cleaned each of the wires individually with turps, re-soldered all the connections, re crimped all the crimps, then spent ages taping it all back together in one big pretty black loom.

Runs sweet now. I'm pretty certain it was a dry solder join on one of the earth splits.


Thanks everyone for your help and advice.

[gijoe1313]

Good work that man! How long did it take you to do all that? And did you take pictures?

[Winter]

Took two days, but I was working 9-5, so two evenings really.

I took a few snaps, I'll find them tomorrow or monday. It really is a massive mess when all those wires are not taped together!