GN250 charging system?

[Fast Eddie]

Trawled through some old threads but this will be quicker for me.

Got the girlfriend an '05 GN250, thought they are supposed to be reliable wee bikes good for learners. Anyway, managed about 1.5 hours of riding before battery drained and engine stalled.

Battery out, its brand new, charged it over night back up to 12.9V resting.

Battery in bike at idle/2,500rpm sits about 12.4v and at 5,000rpm sits about 12.2V so obviously not charging, if you put lights on etc it goes down further.

I'm trying to test the generator/ac stator but the photocopied manual has images which are too faded to see whats going on. Have included some images, is the plug I am holding the correct 3 wire plug that is coming from the stator/generator.



I have tried to get both an AC reading and a resistance reading across the 3 points but nothing at all on the multimeter.. so thought I had the wrong plug or something. It just doesnt register at all on the multimeter.

What else should I be doing to trace the problem.

And anyone have any parts avail? - the mrs is fairly bummed having saved and spent all the cash she had on the bike only for it to die on her an hour later and the prev owner not really going to come to the party in the way of helping with cash. bit of a bummer.

[ducatilover]

Have you got the multimeter set correctly? A lot of cheaper ones will not measure AC, I found this out the dumb way trying to test my stator.

Is there a circuit between any yellow wire and a ground? If so, it's fucked.
If you get no resistance there's a break in the circuit (obviously), probably melted wires or a solder joint had died.

If your stator is poked, it's not the most entertaining job to re-wind one, but it's easy and cheap.

[nzspokes]

read the first post in this. http://www.kiwibiker.co.nz/forums/sh...shooting-steps

PDF on there is very helpfull.

[Fast Eddie]

Have you got the multimeter set correctly? A lot of cheaper ones will not measure AC, I found this out the dumb way trying to test my stator.

Is there a circuit between any yellow wire and a ground? If so, it's fucked.
If you get no resistance there's a break in the circuit (obviously), probably melted wires or a solder joint had died.

If your stator is poked, it's not the most entertaining job to re-wind one, but it's easy and cheap.

I tested my fireblades charge system, batt, stator AC output and resistance and the reg/rec resistance with same multimeter and got correct readings.

yea well thing is im just not getting reading at all when i prob the stator output plug eh.. im sure its contacting, the needle point from multimeter to the plug, its a little tight..

but yea, pain in the ass. I rung local suzuki joint they just said reg/rec prob failed dont worry bout stator haha, so not much help from them yet. reg/rec is 200 bucks too, pricey bastards its just a gn

[Fast Eddie]

read the first post in this. http://www.kiwibiker.co.nz/forums/sh...shooting-steps

PDF on there is very helpfull.

cheers! will get to it

[Fast Eddie]

If your stator is poked, it's not the most entertaining job to re-wind one, but it's easy and cheap.

hehe cheers, will prob pm you for more details if it comes to that,

thanks for the checks to perform, like the above post i just get no reading at all aye, I probed all over the place both resistance and trying to ground and the multimeter just doesnt register which makes me think I have the wrong plug or the meter probes arent getting in deep enough to contact. anyway. they look like that are, its just a tight plug.

if i cross the leads etc it registers so its just a pain. I'd rather get some sort of reading than just nothing

[Fast Eddie]

read the first post in this. http://www.kiwibiker.co.nz/forums/sh...shooting-steps

PDF on there is very helpfull.

that was a good post, thanks. The two pdfs contained within are also useful. Have pretty much done all that is suggested tho, so not sure why I can't get reading at all from stator plug.. keep thinking I have the wrong one or something.

Apparently it should either give some inconsistent ohm reading for resistance or at least say open loop or some sort of response, same with continuity, and ac voltage output but it just doesnt register. Bastard.


but, on the side, if anyone has a reg/rec or knows of one for less than $199 I'll be keen on it. just a straight plug in/mount to original bolts.

[Fast Eddie]

mint, prev owner will go halves on reg/rec cost.. so hopefully its that, hes swinging 100 slides into the acc. good man

[ducatilover]

I tested my fireblades charge system, batt, stator AC output and resistance and the reg/rec resistance with same multimeter and got correct readings.

yea well thing is im just not getting reading at all when i prob the stator output plug eh.. im sure its contacting, the needle point from multimeter to the plug, its a little tight..

but yea, pain in the ass. I rung local suzuki joint they just said reg/rec prob failed dont worry bout stator haha, so not much help from them yet. reg/rec is 200 bucks too, pricey bastards its just a gn

Can't you trace the wires from the stator? If it's coming ut the loom and plugging in to the reg/rec it should be the right one.
My guess is; if you're getting no readings you've got a rooted solder joint (they're probably a wye wound/connected set up, so the solder joint on one end will drop the circuit to all). Usually when the coating on the wires burns off you'll have it earthed out.
It's easy enough to whip the stator cover off and have a perv.

[BASS-TREBLE]

Did you notice the Reg/rec getting too hot to touch when you did the charging tests with it running?

I remember when I had a GN and i had similar issues (would just cutout, so charge overnight and then would only go for half an hour or so)

I had the stator rewound etc which didnt fix it.

Long story short I needed a new reg/rec, was something just under $200 from suzuki if I remember correctly.

[Fast Eddie]

Can't you trace the wires from the stator?

can't yet, will take the tank off and see, the wires join up to like a central sleeve/casing so kind of hard to see whats going on but yea will try trace the wires later.

figured someone who may have done this before on a GN can look at the photo posted n tell me its the plug haha.. being lazy, got things to do on the aprilia and blade as well.

no wires look burnt out or damaged etc.. hoping just reg/rec and there is no corrosion on the bike or any wires or points that are visible.

anyway, will get there eventually. Cheers fellas

[Fast Eddie]

Did you notice the Reg/rec getting too hot to touch when you did the charging tests with it running?

I remember when I had a GN and i had similar issues (would just cutout, so charge overnight and then would only go for half an hour or so)

I had the stator rewound etc which didnt fix it.

Long story short I needed a new reg/rec, was something just under $200 from suzuki if I remember correctly.

yea 199 for a new one, kinda pricey but oh well.

having problems testing stator but yea will prob just replace the reg/rec blindly and hope for the best. Can't be bothered pissing around with it too much to be honest. Her bike not mine haha.

[Fast Eddie]

If your stator is poked, it's not the most entertaining job to re-wind one, but it's easy and cheap.

jesus, hope it is easy and cheap to do cause if its the stator the suzuki dealer wants 503 odd dollars for a replacement part.. eeep!

[FJRider]

jesus, hope it is easy and cheap to do cause if its the stator the suzuki dealer wants 503 odd dollars for a replacement part.. eeep!

Thats half the cost of a "new" GN ...

[Fast Eddie]

Thats half the cost of a "new" GN ...

bingo.. trademe has a couple of offerings.. will see how we go!

bloody hell, i was thinking these were all time reliable learner bike haha! I recommended her to buy it so feel kinda bad it broke down after an hour - oops