SuzukiSavage.com - Starter relay and Rectifier

easymoney

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Starter relay and Rectifier
12/31/24 at 08:46:20

Where is best place to get a rectifier for my 2013 S40/Savage/Boulevard?Any tips or warnings for that brier patch?
Also I noticed my starter relay is less than perfectly free of corrosion at the terminals. I'd like to get it out to do a good cleaning job, but that looks like I would have to remove everything but the engine to get to the mounting bolts. Is there a better way?
Thanks all!

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ThumperPaul

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Re: Starter relay and Rectifier
Reply #1 - 12/31/24 at 16:44:54

I like Partzilla, but.....

https://www.partzilla.com/catalog/suzuki/motorcycle/2013/boulevard-ls650-s40/...

I'd buy this one for the price. The part # is a little different (32800-24B00), but it was the part number that was superceded by 32800-24B11. Same part. It'll work.

https://www.ebay.com/itm/116410405918?_skw=SUZUKI+OEM+RECTIFIER+%7C+32800-24B...

You can get the relay out without removing a bunch of stuff. It's a tight squeeze, but it can be done.

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2026 Houston, Texas Gender:	Re: Starter relay and Rectifier Reply #2 - 12/31/24 at 16:54:57 Here's the same rectifier for a few bucks less ($25.57). https://www.ebay.com/itm/405281696098?_trkparms=amclksrc%3DITM%26aid%3D111000...
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easymoney YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 29	Re: Starter relay and Rectifier Reply #3 - 01/10/25 at 11:13:32 Looks like the rectifier is not the problem, or at least not the only problem. No AC voltage on the yellow wires. I took 9 bolts out of the stator cover, but it won't come off. What is the center thing with the slot? I have an on-line service manual but have not been able to find a picture or mention of it?
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ThumperPaul

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Re: Starter relay and Rectifier
Reply #4 - 01/10/25 at 11:20:50

The center plug is to access the crankshaft timing marks. You don't have to remove it.

The magnetism of the alternator can hold that cover on there pretty tight. You gotta give it a pretty good pull. If somebody used sealant around where the stator wires exit the case, that can get stuck too.

Feel around the edge of the case cover, there are a couple pry "ears" that you can grab onto with your fingers a little (or pry gently with something).

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StatorCoverBolts_001.jpg

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ThumperPaul

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Re: Starter relay and Rectifier
Reply #5 - 01/10/25 at 11:24:14

When you get in there, an important washer is probably gunna jump off it's gear and be hiding in there somewhere. It might be stuck to the alternator due to magnetism, it might get stuck to the case, it might cling about anywhere, or hit the floor. Once you find it, make sure you reinstall it on the correct gear. See photo. I learned this the hard way..

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Anti-backlash_gear_washer_Precaution_2.jpg

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2026 Houston, Texas Gender:	Re: Starter relay and Rectifier Reply #6 - 01/10/25 at 11:29:46 If you remove that plug on the side of the case, this is what you'll see. This is with the timing marks lined up (or really close) to top dead center. Sorry, not a great photo.
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ThumperPaul

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Re: Starter relay and Rectifier
Reply #7 - 01/10/25 at 11:36:22

Here's the stator and pickup I bought and installed. It worked just dandy and was way cheaper than OEM. It also has the correct length wires (like 36"-39"). I can't remember the exact length. Many of the aftermarket stators have only 12-18" wires and then you'd have to solder/splice and re-use a section of your old wires that connect at the rectifier end.

https://www.ebay.com/itm/145045040616

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easymoney YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 29	Re: Starter relay and Rectifier Reply #8 - 01/11/25 at 12:56:49 Thanks for the quick help. Cover off. A few crispy spots on stator. I ordered a new stator and gasket. Hope it goes to plan from now on. Thanks!
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easymoney YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 29	Re: Starter relay and Rectifier Reply #9 - Yesterday at 17:26:05 Thanks Thumper Paul. The e-bay Chinese stator works great. So far any how. By the way, in all the how-to's on this project, I don't think anyone mentioned that when you pull the alternator cover almost ALL the oil falls out. I had the big oil change pan in place but really didn't know how much to expect.
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ThumperPaul

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Re: Starter relay and Rectifier
Reply #10 - Today at 05:07:14

That’s good news!

Whoops! Can’t assume the obvious. Yep, there should be oil in there and it should be drained first. Shocked

Good thing you had a catch pan ready.

Watch the rubber grommet area, where the wires go into the case/side cover. Some of the aftermarket ones aren’t well sealed and prone to leak. DragBikeMike has one with virtually no “rubber” (or whatever it’s made of). I had one that wasn’t fully sealed and occasionally dripped out oil.

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2026 Houston, Texas Gender:	Re: Starter relay and Rectifier Reply #11 - Today at 05:17:03 Here’s an example of a good one. The rubber (maybe it’s teflon) tightly seals around the wires.
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