Thanks guys. Hey Miles...... my bro has owned the bike for 4 years and it was pampered before it came to us. It still has only 17,000 miles on it, and never gave any trouble at all and when he had no car the Max was his daily ride and was faultless.
The problem started when he wanted a clutch upgrade and fitted a new Barnett clutch. The side stand safety system wasn't operating properly so he ordered a new electrical part which cured that problem. The bike is electrically standard apart from a larger headlight from the company Exactrep and it still has it's completely standard H4 bulb. It has heated grips but we have disconnected them.
After the clutch replacement he took the bike out for a spin and had to be rescued. The battery which was only two years old was drained. We then checked the charging and that's how the story began.
The new battery can happily sit for a week and still show a reading of 12.6 volts, so once again we assumed that there was no discharging going on.
From cold starting the voltage at the battery reads minimum 13.5v and up to a max of 14.2 v at 2000rpm. This remains constant even with the headlight on, until that fan kicks in. The voltage immediatley starts to drop into the 12 - 13v region. After the first running of the fan the voltage comes back to almost normal but as the fan kicks on and off for 2nd, 3rd and fourth time, the bike engine is stumbling the volts are 12.5v approx and eventually dies. Once she completely cools and is restarted, the reading at the battery is back to a healthy 14v and the bike runs sweet!
Yes we did clean and change out the fuses. We also ran her with the headlight fuse out to see if we saved a few volts, she might overcome the fan but it made no difference.
I am not sure Miles if we did and R/R diode test when warm, we've been round in circles so many times i have forgotten what we've done. Hopefully eliminating the stator made us think that the new r/r was faulty but didn't know how to perform a test that would be specific to the r/r and be a relaible finding!
If i hadn't sold my Max it would be so easy to swap and eliminate faulty parts!
My bro is so frustated, he was mumbling about buying another new r/r.
On a brighter note, my bro asked me how long have i known Miles Long, and how come he has my picture as his avatar and then almost pissed himself laughing.
Explanation..... I got new dentures and they bloody hurt so I haven't been wearing them and have no front teeth and had just grown a beard. Except for my bald head the likeness is pretty good...lol
sdt354....... When we tried using the Suzuki r/r we ran the wires directly to the battery and assumed the earth was adaquate