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skywalker65 wrote: Might be able to shed some light on this for you as I've just done an absolute pig of a charging fault on one of our bikes with the same symptoms. Would charge ok when cold but when it warmed up it stopped charging.
Alternator function was ok thank god cos it's an engine out on one of these to replace it. As was the regulator / rectifier
Turned out 1 of the 2 wires from the output side of the regulator / rectifier was the culprit namely the earth wire. The resistance of the wire was altering due to the amount of current. You could measure the voltage and watch it steadily drop at the battery.
So I'd be looking at the wiring output from your alternator or main earths and see if the resistance alters from when it's cold / hot
I had exactly the same fault on my 400 Honda, with exactly the same solution as you
The voltage at the regulator was spot on, but at the battery just kept falling.
I rewired from the regulator directly to the battery (live and earth while I was at it) to cure it.
I think it is just a corroded joint somewhere in the wiring harness.
If it suddenly breaks, go back to the last thing that you did before it broke and start looking there
The following user(s) said Thank You: GuardianAngel
GuardianAngel wrote: I dont have a spare Jimny sized battery, so I might just bite the bullet and get one and see. Out of interest, is it possible to fit a higher output alternator like off a Vitara or something?
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I've fitted a larger alternator to mine can't remember which suzuki it was for but I'll check later.
Edit: found it 2004 SUZUKI LIANA 1.6 LITRE PETROL DENSO ALTERNATOR 31400-80G1 . It was more powerful than the one I took out.
skywalker65 wrote: Might be able to shed some light on this for you as I've just done an absolute pig of a charging fault on one of our bikes with the same symptoms. Would charge ok when cold but when it warmed up it stopped charging.
Alternator function was ok thank god cos it's an engine out on one of these to replace it. As was the regulator / rectifier
Turned out 1 of the 2 wires from the output side of the regulator / rectifier was the culprit namely the earth wire. The resistance of the wire was altering due to the amount of current. You could measure the voltage and watch it steadily drop at the battery.
So I'd be looking at the wiring output from your alternator or main earths and see if the resistance alters from when it's cold / hot
That is very useful as I too have a similar problem.
How quickly should the charging system get a battery charged assuming a battery just about turns the engine over when it is a cold start?
Bit difficult to say really. Depends on how much is being taken out of the battery to power consumables etc. Assuming the battery and charging system is ok then I'd say possibly half an hour or so of steady driving.
If my battery was that flat though I would personally charge it with a decent battery charger. Charging systems really only exist to keep everything topped up so to speak rather than recover almost flat batteries
skywalker65 wrote: How quickly should the charging system get a battery charged assuming a battery just about turns the engine over when it is a cold start?
Charging systems really only exist to keep everything topped up so to speak rather than recover almost flat batteries[/quote]
Yes that would be my thinking. My commute is only ten minutes or so and it definitely does not top up a flat battery.
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