Reply To: GV650 FI 2002 – REGULATOR / RECTIFIER Instant overheat

[Zargoo]

Hey,

Thanks for the detailed reply, was working on it yesterday again, and checked the stator again and it was at 5krpm 80VAC so that was fine, the 35 I mentioned earlier were while everything was connected and the bike charged.

Now to quickly find what could cause the bike turning off, as I assumed this is an electrical fault (something pulling too much amps), I started to disconnect everything, and the weird thing now is when the bike is cold and is started it will work until it’s warm.

Now when it gets warm after some time it starts to drown, I would say hard to describe, but it’s as if there is no spark for one cycle and then runs fine again and then drowns again and so on, and also pops can be heard from the exhaust, so I am pretty certain I now have to look and check the coils, injectors, and spark plugs. If those are fine, it might be an issue with the ECU, as the speedo already was hit by the shorted wires that the bike had when I first got it, aka the random km value.

Also checked again which wires were melted together, as I before fixing it wrote it down, and it was the Red power wire to the ECU with some others, so it might be likely that the ECU also took some damage because no matter what sensors I disconnect while the bike is running and dealer mode is enabled, I never get the FI lamp to turn on.

As after testing some more, I got the bike to die suddenly while nearly everything was disconnected. I disconnected all lamps and even the speedo, monitored the RR amps output and voltage, and it was 14V at 5-7 amps, aka only the fuel pump really running, and the bike just died.

Also, what is weird is it could be an ECU fault, but it does not really align with the fact that it works when cold, but after running for 5-10 mins and getting warm it starts that weird drowning. Also, it is not regular; it’s like it gets no spark for 1 cycle, runs fine for the next 30 seconds, then gets no spark for 2-3 cycles, runs fine again, then for 1 cycle, and so on. And then after it runs for multiple minutes it suddenly dies as if it skipped 5-10 cycles at once.

Maybe you know what this could be.

Also, do you know by any chance what the usual amp usage is on the GV650? Because no matter what I do, a 10 amp fuse on the RR won’t work, as when I measured just the headlight + fuel pump it’s 10A, + blinkers, brake light, radiator fan, it easily gets to 15A, and then when under high RPM it even goes up to 19 amps. The Shindengen RR says it will work at 30A steady, but not sure if the GV650 should be using 20 amps. As I then used a 15A fuse, which under high RPM and high load, aka everything on, also burned. Now I’m on a 20A fuse but not sure what the GV650 usually needs, as I saw upgrade kits that used 10 amp fuses.

Also checked plugs, wires, and relays, and they seem fine, but will probably swap all relays as they could be the cause for the high amp usage, as I did not yet do a voltage drop test on those relays. What I found weird is the installed relays are all 20 amps, but when I checked the parts catalogue and service manual it says those should be 30 amps. And from my measured amps at high RPM, which was at 19 amps, those relays would have worked basically at the limit of their rated amps.

And yeah made sure the service and owner manuals i was using are 2009.