Topic: Don's 81 GS1100e happy Suzuki.

[Don R]

 I swapped to a new battery, when running the voltage remains the same and revving it up changes nothing, the clues are,
 (1) I noticed the voltage regulator wires have been cut and re-connected as if someone didn't know there was a plug-in nearby. Why would that happen? Junkyard V-Reg? Indicating previous issues?
 (2) it didn't re-start easily after a 30 mile ride but I wouldn't think it would go that far just on battery.
 Maybe I just dropped a wire when swapping the old battery. Wishful thinking probably, but a place to begin. Then I'll follow the manual and check everything with my meter.
  And no, I haven't checked the rotor for being spun on the shaft yet. Both engine side covers appear to be newer than the bike, so the dyno coils have also been moved to the new one.

[Don R]

 The rec/reg checks bad, the plug ins were badly corroded and wrapped in balls of tape. That probably didn't help anything. The resistance is equal through all combinations of the 3 wires coming off of the dyno. I need to replace the bullet connectors before checking the volts, they are too corroded to get a good meter reading with potential of ac voltage there.

 The swingarm bolt is also the shorter one. Apparently for a pre-80, shame on me it doesn't say 1981 in the ad. Anyone need a $70, 12" bolt.

[seanbarney41]

Ohhh boy...Suzuki that does not charge properly...you are about to have some fun learning about the very strange Suzuki charging system.  I suggest checking out the GS Resources forum.  There is an easy wiring mod that makes things much more standard and dependable.  Sorry I can't be more informative here as I barely understand the electrics on these.  I will tell ya that when mine was not charging, it was the stator.  But not because of any inate Suzuki engineering flaw, the wiring hold down under the stator cover had come loose and the screws got between the rotor and the field coils and wrecked the alt6ernator...twice!  So if you get in there, be sure and loctite all that stuff!

[grcamna2]

I installed a 'Series Type' regulator/rectifier on my Suzuki's and it's Much Better than the original.
The unit will last many years and charge your battery better than the 'Shunt Type' which is the stocker. The Series Type lets the heat go into the heat sink of the reg/rect rather than 'shunting' the overflow watts back into your alternator windings and roasting them:keeps the stator/alternator coils cooler.

thegsre'sour'ces .com has useful info,but not many of the members are as nice as this forum..

The Polaris side by side and 4-wheelers(look for Polaris listings)have these Shindengen #SH775 units stock and you can find them used on Ebay(these reg/rect units last a long time:durable & reliable)for a good deal;keep looking on the listings for the printed numbers SH775.. in the pics to confirm. I bought a used one and have run this #SH775 wired correctly for years:they last. 
 The best way to wire them is hook-up your 3 stator wires directly to the 3) SH775 connections,rather than color to color through the harness.. 
Hook up the + & - ends of the SH775 directly to your battery leads and you'll be 'golden'.

[seanbarney41]

yeah, I got the shindengen sh775 reg/rec on my gs...it is good!  Also, Camna's post reminded me what is goofy about the Suzuki charging system is the shunted voltage runs through the lighting circuit as well as shunting back to the stator to try and use up some of the excess, so if you ain't running your high beam that stator is gettin' hot!  GSResource's guys believe that is why the oem suzuki stators don't last and that upgrading your reg/rec to a series type over the stock shunt type can actually result in lower oil temps!  Wiring the series reg/rec as Camna posted fixes all this.

[Don R]

  Both of the engine side covers appear to be newer so there's one more reason to take the dyno cover off. To check the appearance of the stator and the status of the bolts, at least one previous owner was a serious over-tightener so there's that.
  Thanks for the heads up on the charging system, I hadn't found that in the GS resources yet. This is exactly the kind of info I was hoping for.
  Jegs still has me hanging on the K&N pod filters, apparently they didn't know that no one can get them. I'll buy APE filters once Jegs decides if they will be able to fill the order.

[Don R]

 So far, I'm only finding china made cheap V. reg's. They all seem to be sold by the same guy with a hundred different ads. The roadstercycle web site shows what you guys were saying. He has some kits and possibly heavier duty versions of the same product. Not cheap either.
  Tomorrow night I'm going to see my buddy that works on Harleys in his own shop, I've seen this issue mentioned on Harleys also so he might have a hookup. 

[grcamna2]

So far, I'm only finding china made cheap V. reg's. They all seem to be sold by the same guy with a hundred different ads. The roadstercycle web site shows what you guys were saying. He has some kits and possibly heavier duty versions of the same product. Not cheap either.
  Tomorrow night I'm going to see my buddy that works on Harleys in his own shop, I've seen this issue mentioned on Harleys also so he might have a hookup.

Look for good,solid used ones on Ebay;these rarely burn out.
Look for Polaris 4-wheeler models and then look at their pictures for the mark 'SH775' stamped on the side of the heat sink.

[seanbarney41]

The kz guys often adapt the sh775 too...if you post a want for one on kzrider their is a prolific longtime member who is always turning them up used on ebay.  He will get you the Triumph part number of the wiring adapter that make this plug and play too.  This is how  got mine.

[grcamna2]

The kz guys often adapt the sh775 too...if you post a want for one on kzrider their is a prolific longtime member who is always turning them up used on ebay.  He will get you the Triumph part number of the wiring adapter that make this plug and play too.  This is how  got mine.

I have the Triumph reg/rect SH775 harness,which has the Triumph part# T2500676.
I connected it with standard female blade terminals and plenty of De-Oxit spray;I still have the Triumph hook-up harness in it's bag.
The Triumph harness has lot's of their dialectric grease from the factory on the end plugs which fits the Triumph harness;those will be cut-off when I finally install this SH775 onto my old GS450.

[Don R]

 I did turn up a couple by adding the term "used" to my search. The dozens of china made ones are making a search hard to sift through. 

[grcamna2]

I did turn up a couple by adding the term "used" to my search. The dozens of china made ones are making a search hard to sift through.

See my reply #257
'Polaris preowned' should yield you a few.

[Don R]

 It did turn up one from a Polaris/Indian but it has the part number on it, that's the first one I found with the number, made an offer.
  I'll also run a ground wire from the engine ground to a good location on the frame.

[grcamna2]

It did turn up one from a Polaris/Indian but it has the part number on it, that's the first one I found with the number, made an offer.
  I'll also run a ground wire from the engine ground to a good location on the frame.

I did quite a bit of looking(I needed to find ones with the printed #'s SH775;the last letters after '5' don't matter)before I found the best deal;it took time.

[Don R]

 Good to know, I just bought one with a BA after the sh775.
  I'll have a cheap china reproduction stock type reg for the "chalk it up to experience" file. Maybe I can use it for testing until the sh775 gets here.
  Thanks for the coaching, next time I'll ask first and buy parts after that. L0L!

  Edit: I added a ground wire from batt - to the frame, put star washers under a couple ground connections and got better test volts from the 3 AC wires. Maybe it was a co-incidence.

 The stock replacement V-reg came today I installed it for testing and it got right to 14.6 volts when I started it up. I made up a ground jumper and battery wire to hook the new Mofset reg to the battery and three AC wires when it gets here.

 A few years ago, I bought some 3mm bullet connectors by mistake and kept them for future use. I'm glad that I did, they came in handy on the Suzuki, and the vintage connections crimper is a treat too.

[Don R]

  The seller gave me two black plastic panels with the Suzuki, my brother thought maybe they were part of the air filter box which it doesn't have. Today I googled the part number from the back and it's a front license plate delete cover for a 2000/05 Monte Carlo. L0L. The cheapest one is $50 on ebay, the highest one is over $100.

[grcamna2]

Good to know, I just bought one with a BA after the sh775.
  I'll have a cheap china reproduction stock type reg for the "chalk it up to experience" file. Maybe I can use it for testing until the sh775 gets here.
  Thanks for the coaching, next time I'll ask first and buy parts after that. L0L!

  Edit: I added a ground wire from batt - to the frame, put star washers under a couple ground connections and got better test volts from the 3 AC wires. Maybe it was a co-incidence.

 The stock replacement V-reg came today I installed it for testing and it got right to 14.6 volts when I started it up. I made up a ground jumper and battery wire to hook the new Mofset reg to the battery and three AC wires when it gets here.

 A few years ago, I bought some 3mm bullet connectors by mistake and kept them for future use. I'm glad that I did, they came in handy on the Suzuki, and the vintage connections crimper is a treat too.

I'm glad you re-connected the Ground connections Don;does the GS1100E battery - wire connect to the bottom of the engine case ?

[Kelly E]

The ground wire connects to the top of the case on the right side behind the clutch cover.

[grcamna2]

The ground wire connects to the top of the case on the right side behind the clutch cover.

Ok.

[Don R]

  I just added a battery to frame ground wire. Just a thing I learned playing with fast cars some weird problems were solved with a better ground.

[Don R]

 Did you guys use small spade connectors on the Polaris V-Reg or did you get the Polaris plugs? My small spade connectors are all for tiny wire.

[grcamna2]

Did you guys use small spade connectors on the Polaris V-Reg or did you get the Polaris plugs? My small spade connectors are all for tiny wire.

Don,I used small spade connectors on my SH775 but still have the Triumph wire connector set-up in a plastic bag;the multi plug Triumph connector is less than $20 and they have the exact plugs needed to seal the ends from water.
I used dielectric grease on the small spade terminals  I have the Triumph part #.

[Don R]

 Ahh, I found one, thanks it takes the right combination of terms on ebay, (regulator, rectifier, plug connector for Polaris) I'm gonna let the pay pal cool off for a week or so, I've hit it pretty hard recently.

[BenelliSEI]

  I just added a battery to frame ground wire. Just a thing I learned playing with fast cars some weird problems were solved with a better ground.

So true! I had a Honda Civic that melted a throttle cable to jello because someone(?) forgot to reinstall that extra ground cable……..

[Don R]

  I just added a battery to frame ground wire. Just a thing I learned playing with fast cars some weird problems were solved with a better ground.

So true! I had a Honda Civic that melted a throttle cable to jello because someone(?) forgot to reinstall that extra ground cable……..

My Firebirds gauges would all twitch and the indicators would glow, a ground from the firewall to the printed gauge board cured it.
 My brothers 70 Dart acted really crazy, lights going on and off, start/no start. It turned out it didn't have an engine to battery or body ground wire, I added that and also added a battery to a radiator support ground wire, he had added relays to the headlights but they had a bad ground also.