Question about 1999 Suzuki GSX-R 750 X

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Rectifirer plug melted

I have a 1998 gsxer 750 i replace the battwas stator and and the recitifier because it was not chargeing but now the plug on the rectifier has melted and im geting a reading of 10 volts on the ground wire that comes off the rectifirer

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Scape to bare metal and reground all ground wires then make sure no hot wire has melted its insulation and is touching metal on ur bike,

Posted on Aug 08, 2010

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1 Answer

06 gsxr 600 stalled at a stop light and wouldn't restart, already replaced the battery and stator?


It sounds like its possibly a bad regulator/rectifier. I have posted a link to a video on how to test your regulator. How to test 2 plug Regulator Rectifier for K6 K7 GSXR 750 600 1000

Jul 12, 2014 | 2007 Suzuki GSX-R 750

1 Answer

1997 Kawasaki VN 750 Vulcan not charging the battery


Hi, Ethan before testing any electrical component in the Charging System it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries.
1. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
2. To check the regulator unplug it from the stator. Take a test light and clip it to the negative terminal of the battery and then touch first one pin and then the other on the plug that goes to the regulator. If you get even the slightest amount of light from the test light the regulator is toast.
To do this with a meter: black lead to battery ground, red lead to each pin on the plug, start with the voltage scale higher than 12vdc and move voltage scale down in steps for each pin. Any voltage is a bad regulator.
3. On the other part of the disconnected regulator plug. Set the multimeter for Ohms x1 scale and measure for resistance across the pins of the stator. You should read something around 0.1 to 0.2 ohms for a 32 amp system.
4. Then check for continuity between each pin on the plug and frame/engine ground. The meter needle should not move (infinite resistance)(digitals will show infinite resistance) if the meter needle does move (indicating continuity)(digitals will show some resistance), recheck very carefully. If the meter still shows continuity to ground the stator is shorted (bad).
5. Set the meter to read A/C volts higher than 30 volts (the scale setting for voltage should always be higher than the highest voltage you expect or you may fry the meter). Start the bike, and measure from one pin to the other on the plug (DO NOT cross the multimeter probes! - touch them to each other). You should read roughly 16-20 vac per 1,000 rpm.
6. If the battery was good under load test, if the stator is NOT shorted to ground, and the stator is putting out A/C voltage, then the regulator is bad (most likely even if passed step 2)
For more information about your question and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Battery not charging Kawasaki Vulcan Forum Vulcan Forums Simple charging system troubleshooting Kawasaki Vulcan 750 Forum Kawasaki...
Kawasaki VN 750 Service Manual
OEM Parts for Kawasaki
1997 Kawasaki Vulcan 750 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jul 13, 2012 | 1997 kawasaki VN 750 Vulcan

1 Answer

Gsx r 750 1998. Battery holds charge when riding with lights off. But not with lights on. Stator or rect/reg??


Definitely a charging issue. Always check the battery first, I prefer a gel cell battery over acid. Battery must be good and strong to charge properly. This charging system is so small , it only operates enough to maintain battery voltage. Normally it wont charge a weak battery, so start there first. you can check the voltage coming from the stator, at 3k RPM you should be getting around 60-80 volts per leg. If each stator leg checks within these results, it will be a good stator. The reg/rect is not something I can tell you how to check on the bike. We have a stand alone system here where we bench test them off the bike to eliminate the rest of the system to test Just the reg/rect.
I have these stators here new also have the reg/rect, both have a one year warranty. If you need more help let me know. Thanks

Feb 21, 2012 | 1998 Suzuki GSX-R 750 W

1 Answer

Hi I have a 2001 Honda shadow ACE motorbike. There are 3 yellow wires going from the alternator to the voltage regulator through a 3 pronged plug. They have become very hot and fried themselves at...


3) there may be damage that has caused this
2)doesnt matter which yellow wire
1)maybe fried regulator or stator coils or aged insulation which has allowed a short between windings

The three wires are the 3 poles of the stator windings,

Fix the wires and plug first(electronics shops will have suitable 3 or 4 pin plugs to use)
get a multi meter and check resistance, any pair should have same resistance, non should short to ground.
with the bike running they will produce AC current (maybe 50-60vAC)again any pair.
If you are getting good AC voltace, then put the meter across the battery 12vDC engine stopped should rise to 14 vDC (about) when engine revved to 3000rpm

No AC -new stator
No DC-new regulator
Note voltages are estimates, many bikes run very similar charging systems

Jun 08, 2011 | 2001 Honda VT 750 CD Shadow A.C.E. Deluxe

1 Answer

I replaced the stator and rectifire in my 2oo1 r6 batt is still not charging why


check the voltage across the battery, should be over 12v engine stopped, and 13-14 v with engine running.
make sure the battery will accept charge from a battery charger. the stator should produce roughly 50vAC from any pair or the three phase wires( they are the three that are the same color)

Apr 15, 2010 | 2001 Yamaha YZF-R6

1 Answer

Hi,I have a 1982 V45 sabre,the problem is the stator plug is getting really hot.checked the charging and it's between 13.2-13.9.is it normal for this plug to get hot?


Yes some heat is normal, not so hot that it melts. Your voltage from stator is AC not DC,the voltage you read was after voltage regulator.To check the stator output unhook the wires from stator,run engine at 1,500 rpms as you read Volts AC on your meter,read from one stator wire to the other (do not use black to ground) untill you have tested all the combinations,write down the different set of numbers.You should read around 45 or 50 volts AC on each set. The high temp on the wire is more likely the result of wire connections needing to be cleaned and treated with dielectric grease to keep out moisture and deture corrosion.With good clean contact the wire will have less resistance and be cooler.The hot spot is usualy the weakest. OK well hope you get it done soon,Ride safe!

Apr 08, 2010 | 1982 Honda VF 750 S

1 Answer

Stator wire melted 98 GSXR 750


I guess its the regulator/rectifier thats pushing too many volts down that wire. Try another unit after fixing the wire

Sep 10, 2009 | 1998 Suzuki GSX-R 750 W

3 Answers

Stator wiring overhaeting


just a suggestion but your grounds are ok

Mar 22, 2009 | 1998 Suzuki GSX-R 750 W

4 Answers

Battery is not charging for atv suzuki atv


try replacing your rectifire becuase that is what charges the battery

Mar 09, 2009 | 2001 Suzuki Burgman 250

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