T500 electrical gremlins

All to do with wiring, charging or just trying to figure out whats gone wrong.

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kall399
On the street
Posts: 43
Joined: Wed Sep 23, 2020 10:33 am
Country: Finland
Suzuki 2-Strokes: 1973 T500

T500 electrical gremlins

Post by kall399 »

SO my T500 left me on the road yesterday....cut off from 80kmh... the battery only gave out 150 milliamps :wth: at 12,9v I guess the agm battery didn't last so well but at the same time it blew every bulb on the bike so not under charging but over charging I would assume... all this started when the negative battery cable broke off a few weeks ago didn't stop the bike then but I assume it might have broken the voltage regulator somehow :? ¨the stator put outputs 20 to 50 v when disconnected from the rectifier so I'd assume that ok. If anyone has any ideas I would like to hear them
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jabcb
Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: T500 electrical gremlins

Post by jabcb »

The T250/GT250/T350/T500 use the battery as a voltage regulator.
The T500 & later GT250 also have a voltage regulator only intended to limit voltage to 16V — haven’t seen anything about its performance without a battery.

That 16V is too much for AGM batteries. Looks like you probably ruined the battery.
And without a good battery, the voltage got high enough to burn out all of the bulbs.

The preferred solution is to upgrade to a modern rectifier/regulator + a new AGM battery.
Or switch to an old-school conventional battery + make sure everything you have is OK.

There are some forum topics about upgrading to a modern rectifier/regulator. This will limit voltage to around 14.5V. Plus the modern part is a little more efficient so you will get a bit more alternator output.

Let me know if you want to do the upgrade & I’ll find the topics for you.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
kall399
On the street
Posts: 43
Joined: Wed Sep 23, 2020 10:33 am
Country: Finland
Suzuki 2-Strokes: 1973 T500

Re: T500 electrical gremlins

Post by kall399 »

The voltage must have gone up quite a bit since the led headlight that is supposed to be good at 12-36v also blew :shock: I also bought a 4 wire modern reg. rec. for a snowmobile or some such. I was not exactly sure of how the original voltage reg. was supposed to work and assumed ((incorrectly) when buying a new battery a few summers ago that an agm battery would do fine :oops: well it lasted 2 summers so that's something but thanks for clearing up the correct functioning of the thing :up:
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jabcb
Moto GP
Posts: 4241
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: T500 electrical gremlins

Post by jabcb »

You might have also burned out the voltage regulator.
Also, if your headlight was one of those cheap Chinese clones, then the 12-36V is a claim that may be unrelated to reality.

This morning I was looking for a T250/T350 battery on several parts retailer websites. The T250/T350 does not have a voltage regulator.
Got recommended selections including AGM & lithium batteries. Lithium batteries are even pickier than AGM.
No telling how many people have been screwed over by this issue.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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