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Discussion Starter #1 (Edited)
Intermittent/ Fluctuating Voltage Problem (South bound for Argentina)

G-day,
I've been McLurking on this site for over a year now and have read some awesome stuff, and haven't until now needed to post a question that I haven't found and answer too!!
So, I'm Two up with my Girlfriend heading South on my way from Canada to Tierra Del Fuego (on a 2007 Vee). I'm Currently in Guadalajara Mexico, fine place too. The problem started a few days into Mexico coming down the pacific coast in the 100+ heat on Highway 15. Started to notice the volts drop on my ChargeGuard voltmeter. They normally sit at 14.8 all day every day (36k miles on the clock, 16k are mine). The volts dropped when I slowed to pass through a village (low revs) but then wouldn't snap back up to 14.8 once back up to 4500rpm highway speeds:confused: they would get up to 12.9/13 then gradually climb .1 volt every 15 minutes or so. So this made me a little concerned, and I opted for a new battery, a fresh Yuasa YTX14-BS. New battery and bang, 14.8volts!!! Well... this only lasts on a cold start and then once the engines hot the volts slowly drop down and slowly raise up. They can drop to 13volts and then slowly climb back to 14.8 - if I'm lucky - many times over the course of a 300+ mile day. My question is, does this sound like my R/R?! or faulty battery?! or my bloody Stator/Generator or a possible loose magnet on me flywheel?? It seems so intermittent that I'm thinking Battery or R/R. As I'm in mexico taking it into a shop ain't as easy as it would have been back in the states :headbang:
Thanx in advance for any feedback!
Cheers, Sean
 

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$Whatever$
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Sounds like what happened to my 06.... ended up being a bad stator....
 

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Could you coordinate in the next big town just to have
stator and mosfet r/r waiting for you.

It is only a couple of hour job if you have the parts. A fuel injected anything needs real power. Battery only is only good for miles... not like the old days.

You would be standed who knows where

I also fear for the moving magnets but thats me
 

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You may be in luck, being in Mexico...

...chances are greater that you can find someone that can rewind your stator for you rather than replacing it with the Suzuki one.

I've had a few failures over the years on my '03.
I recently went to the MOSFET Reg/Rect and the last time that I had a stator failure, I had it rewound by an 'old school' shop. The recommended that it be covered in epoxy for longevity. The phone conversation that I had with him prior to sending it they said that they'd use slightly larger wire than stock and likely pack more on, too...!

If you get in a pinch, I've got a spare 'normal' factory Suzuki R/R in a box...








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Discussion Starter #5 (Edited)
Thanx for the replies folks... as it turns out... some of the magnets are loose on the fly wheel:headbang:.... FAAAAARK.... so currently looking to find a new flywheel in the states as Mexico don't got one:headbang: I can't believe this is an ongoing issue for DL1000's and Suzuki won't fix for free... if I hadn't found the issue when I did, I could have ended up with bloody all sorts of crap flying around my block and have been up for full rebuild... what a joke...
 

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$Whatever$
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My magnets were all good........... One guy was saying the flywheel is a backordered item.... Good luck..........
 

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The flywheel thing has me with the heebee jeebees. I will be inspecting the flywheel on my 06 this winter

I do believe that the loose magets could be reglued back in

I would have faith in JB WELD epoxy at any autoparts or good hardware

Clean with brake clean

Sand attachment areas magnet and rotorapply the epoxyan even coat

Then push it in in one motion maybe with a little side to side wiggle and

GENTLY clamp

Magents are as brittle as crackers the slightest impact or dropping and they will shatter

Even if magents on my bike look fine I will consider filling the gaps (grout) with JB Weld to help hold them for the future

Try Safari Cycle in Long Beach, Cali they might have a used one cheap and fast
 

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While I'm not going to loose any sleep over the charging system on my Vee, I am going to look into installing a voltmeter this winter to keep a closer eye on things.
 

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Mex City

I live in Mexico City if you need any help send me a mail garrydymond @prodigy.net.mx
I thought I needd a rotor last year and it was a 3 week wait if ordered in Mexico. If you get one in the States you will have to pay import duty if you ship it DHL etc or wait 3 weeks to a month if you ship USPS.
If you want to come to Mex City you have a place to stay with us.
Good Luck

Garry
 

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I just went thru this on 07 V with 36,000 miles on it ( dead battery again thread).I decided to sell it and buy a old school bike that I have had many of,a 1982 suzuki GS850 and guess what??,they had the same problems back then that the modern Stroms still have !!!!!!:headbang:.COME ON SUZUKI,fix the problems that have been going on for over 30 damn years !!!!!!!!
 

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Discussion Starter #11
EVERY magnet is sliding around that flywheel... umberloodyleavable!!!! 1 month back order from Mexico.... FAAAARK:headbang::headbang::headbang: oh well, just have to find one online an get it shipped ASAP to me here in Guadalajara...
 

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Discussion Starter #12
thanx again for the input folks... @ Garry- thanx amigo... if we pass through Mexico City I'll give you a buzz...
Thinking of ordering the rotor from Suzuki in the States and getting my old man to send it as a gift... I hear the import duty in this country is OUTRAGES:furious:
Still in shock that this has happened to my trusty steed... I love my Vee, and apart from this issue it has done the last 36k miles hassle free... I just hope this issue won't reoccur... I'm wondering if a significant hit to the bash plate ( I have a aftermarket steel one installed) from underneath could dislodge the magnets:confused:... I hit a decent concrete bump in the road in Los Mochis after a days riding in 100+ heat... in hindsight methinks this is around the time I noticed the volts starting to drop... I didn't think anything of it because a bash plate shouldn't transfer the shock into the engine:confused:
 

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Sorry man

If anyone has the old one with "good" magnets (not cracked or chipped) I would like to check them out and I will see if I can find an epoxy that would be hot oil proof and see if a repair proceedure could be developed

If there are forces contributing to failure I assume its rapid changes in rpm probably like locking up the rear in a panic etc.

More than likely the epoxy degrades to crap over time and hot oil. Some epoxies will simply melt like a plastic at higher temps

Lone Shelby ? together there is a set
 

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I checked with my Local dealer here in Ontario and he says there is a stator in stock in the Toronto Warehouse. He could have it here for Tuesday or Weds. If you want I can make arrangements to get it and have it shipped out to you. List price is $312 in Canada. I can get it for $285 plus taxes (13%) totlaing $322.05 (Can$) I have no idea what shipping would be but would be willing to set it up for you if you like.


If you want to go ahead please PM me. Part number is 32101-17G00 please confirm this is the right part.


..Tom
 

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Discussion Starter #15
Thanks Tom, I've found a Rotor and its being shipped to my Dads in AZ. He's going to FEDEX it as a gift, so this should slip through and avoid the 100%+ Mexican Import and duty TAX's... my Stator is A ok... so should be 2/3 weeks... fingers crossed... guess its all part of the Adventure! thinking of getting my rear shock rebuilt while I'm waiting... Miyagi is riding way low wit me an Blossy and all our luggage... and I'm pretty sure the hit to my bash plate was responsible for knocking the magnets loose on the rotor... I've also ordered some 1.5 inch raising links for the rear shock... found an amazing Suzuki specialist here in Guadalajara... they even have a Dyno!? so kinda lucky it happened here before we started getting into the rougher roads of Central America!!
The name of the shop is "MotoChavane" run by a frenchman named Xavier Chavane.... awesome shop if anyone is riding through this way on a jap bike... they have another DL1000 in the workshop and many more large Suzuki bikes...
 

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If I were in this situation, I'd try JB welding the magnets back into place, although had mixed results bonding epoxy to aluminum.

Would be interesting to know what the oem bonding agent is for the magnets.
 

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Thanks Tom, I've found a Rotor and its being shipped to my Dads in AZ.
...
Had a brain fart.. read Rotor, thought Stator.

Glad you found a solution!

..Tom
 

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I checked with my Local dealer here in Ontario and he says there is a stator in stock in the Toronto Warehouse. He could have it here for Tuesday or Weds. If you want I can make arrangements to get it and have it shipped out to you. List price is $312 in Canada. I can get it for $285 plus taxes (13%) totlaing $322.05 (Can$) I have no idea what shipping would be but would be willing to set it up for you if you like.


If you want to go ahead please PM me. Part number is 32101-17G00 please confirm this is the right part.


..Tom
I could use that stator, where did you find it?
 
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