Okay, get this, I just rebuilt the motor, completely, new clutches, checked the stator, ect, new rings, and timing chain, valve job. ect. Now, It charged fine for the 1st ten miles of riding it here in the yard. then, I noticed it wasent charging. the battery was dead. I have 2 voltage regulators, (had charging probs before) Well, my new voltage regulator seems to overheat, ALOT. (it will burn me) and when you put it on a battery charger, and start the motor, it seems to hold its own, but with the headlights on, it seems to drag the battery down. I've tried everything... checked ALL plug ins.. checked the regulators...And it seems to me, if my stator was bad the regulator wouldn't be getting hot. So, WHAT could be my problem? I'm ready to give up on it and the headlights are two 25 watt headlights out of a kawasaki.

I'd hate to have to junk a suzuki with 10 miles on the rebuilt engine. lol
Also, Are the axles bad to slip on these? where they go onto the main drive gear? I can't tell if its spinning or slipping when I go on a really hard pull. It feels like it skips just a second, then catches and goes on... Wouldn't it do that all of the time though if it was bad enough to slip?

 

come on guys, I need help here. surely somebody knows

 

Hello sir, I'm really not familiar with the electrical setup on a suzuki, but from what I've seen most all atv's seem to have a similar system. Having said that, I would check the stator output for AC voltage output, I know on my honda you will see between 9-30 VAC at idle and up around 30 VAC at 5000 RPMs. I would also check continuity between the stator output wires, none should show continuity to ground, and I believe there should be around 2 ohms of resistance between the stator legs. At least those are the aprox. values shown in the Honda Service manual. I know on my machine these test can determine wither or not you have a stator or rectifier/regulator problem. Hope this is some help, if not sorry, and I will try to help anyway I can.

Best Regards,

Max

 

Send Me a pm with your e-mail address and I will scan a few pages from a manual for you.

 

sunbird80racer2000@yahoo.com