More for my own later reference, but also for anyone who runs into these kinds of problems down the road, I found the r/r test thread (started by constrapolator):
How to test your Voltage Regulator-Rectifierhttp://suzukisavage.com/cgi-bin/YaBB.pl?num=1245984387And another useful thread about issues similar to mine:
HELP! Black rectifier wire melted the connector (started by misterman1)
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1269650762Busy day today ahead of me; can't guarantee I'll get around to any of the tests everyone suggested. Here are the current hypotheses we're testing here (two most likely first):
1.
Fault in the stator. I just ordered an alternator cover gasket and will post pictures once I get a chance to look at the stator. Frayed insulation, broken or exposed wires, or excessive gunkiness will support this hypothesis. But alternator does put out power --- testing voltages at the yellow wires gives me around 100V each at RPM, so I know the alt's at least putting out juice into the r/r. But it's apparently not making it out of the r/r, so that brings me to...
2.
...fault in r/r. Possible causes: not a perfect fit on the boltholes, so it may be subject to undue vibration. Or, crappy r/r (new unit, but aftermarket). I'm getting enough juice to keep the battery at steady voltage when idling, but when I roll on the throttle, the voltage barely increases in proportion to the amount of throttle I'm laying on. I'm definitely not getting 14.something volts at 2,000rpm (but did when I first installed the new r/r). Will test both r/r's (kept the old unit) per the thread I found.
Note: I
did blow a fuse when I first installed the new r/r --- but the fuse casing was cracked from something and probably hasn't been replaced in a few years, so it could have just been a bad fuse. All new fuses; haven't blown any since.
3.
Fault in decomp relay box (suggested by
WD): will test as directed.
4.
Fault in starter or starter solenoid. (suggested by
Cavi Mike) Unlikely, as the problem appears to be somewhere between the r/r and alternator; i.e. the bike starts just fine but doesn't charge like it should. Still worth looking at, since a fault in either component might be contributing to my troubles. Also, my lights definitely don't dim when I start it up, but I never did check out the lights when last my bike failed to start. Will watch out for it.
5.
Dirty connectors, frayed insulation, broken wires, hot spots, and corrosion. (suggested by
Oldfeller) A likely contributor, since I
do live in Florida, and as much as I try to keep my bike covered (don't have a garage), it still gets rained on once in a while. Wouldn't hurt to have another go with the contact cleaner and dielectric grease on every point I can get to on the wire harness.
One or more of these can be true. (sigh) I'm willing to consider appeasing these electro-gremlins with a sacrifice. Ten broken diodes and twenty feet of frayed copper cable? Or are they the kind to demand blood?
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