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Not charging 1980 Suzuki GS 250

I have a 1980 Suzuki GS 250 motorcycle that will not charge the battery when running. Will only run off of the battery. What could the problem be, and is there a manual available to download? @

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  • mazdamx62fly Nov 19, 2009

    We changed the battery the first thing. But thanks for answering us back. Bike has only 8,000 original miles.We were thinking that it might be the stator. Didn't want to spend the bucks if I was wrong.

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  • Suzuki Master
  • 58,369 Answers

Hi, Mazdamx62fly 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.
https://www.ifixit.com/Answers/View/486385/Battery+not+charging+and+tested+stator+and+rectifier+regulator
How to Fully Troubleshoot Your Motorcycles Charging System MotorcycleMD
https://www.tradebit.com/filedetail.php/278345166-1979-1985-suzuki-gs250-gsx250-gsx400-gs450-twins $15
https://www.partsfish.com/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

Posted on May 15, 2019

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6 Suggested Answers

6ya6ya
  • 2 Answers

SOURCE:

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Posted on Jan 02, 2017

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  • 46 Answers

SOURCE: Battery on 125cc Suzuki GS is ok- but not being charged

You need to have stator coil tested.
An alternate problem could be the regulator/rectifier.
Both of these should tbe checked by a dealer

Cheers

Jon

Posted on Mar 05, 2009

  • 39 Answers

SOURCE: How do I charge the battery? I don't have a manual. Thanks!

like he said its just like a car if you cant find it look under the drivers seat and or under the panels under the seat

Posted on May 11, 2009

htechie
  • 146 Answers

SOURCE: Anyone have an operators/owners manual available

Please Rate if you found the above info useful.

Posted on Aug 24, 2009

Testimonial: "Thank you so much for your help."

slave2aslave
  • 302 Answers

SOURCE: Suzuki gs 125 motorcycle - carburettor set up

www.onlinefreeebooks.net/automotive-machinery.../suzuki/

Try this one.

Posted on Sep 23, 2009

mb50sa
  • 80 Answers

SOURCE: i have a 1980 suzuki 850 gs and its not charging

As suggested, check the voltage with the engine running accross the battery. If its below 14 volts you have an issue with the stator windings/regulator/rectifier/wiring.
Do the cheapest thing first and clean up all electrical connections, esp the earths.
A manual will tell you how to test the charging system, but the Suzuki GS range has always had charging issues.
The simplist method is to fit the combined reg/rectifier unit from a Honda CB250/400 Superdream.
Always keep your engine oil topped to the max mark, as this cools the stator.
Dont leave this, it is not unknown for the entire system to fail including the CDI if left unchecked.

Posted on Jun 21, 2010

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