[Diamond Dave]

My 2006 C90T is not charging. I changed the battery, Rectifier, checked the 30 amp fuse(Good) and did a resistance test on the Stator. The Stator resistance test was within tolerances for all combinations. I did the test on the three wires shown in the pic. There wasn't a standard Stator plug and it looks like the previous owner used these crimp connectors. I didn't disconnect them since they were pretty tight and I didn't have time to fix them if they broke. So I tested them while they were connected.
Was that a useless test? The take away is the bike isn't charging. I have ordered a new Stator and should have it in a few days. What else should I check?

Thanks,
Diamond Dave

 

[DCinCT]

you may be aware that 05/06 c90;s did have stator issues...when i got my 05 c90 in 2010 I asked my mechanic if I should replace the stator since the mc still had the original stator...he...suzuki service tech... told me he found the stator issues were running about 50/50 on the affected years...so he advised not to...shortly after the mc died...yep...stator...that occured at 15k...lost that mc in an accident,,,girl blew a stop sign ...replaced the totaled 05 c90 in 2013 with an 06 c90... again mc still had original stator...bought the mc with 8k on the dial,,,that stator lasted till 2018 with 54k on the dial...for a while I thought I was going to be ok with the original stator,,,learned the hard way to carry a spare stator with me when on a trip...place I had it towed to in NH ripped me off royally...is what it is...good luck finding the issue, may also want to check here...

Suzuki 1500LC / C90 Owners Group-Classic (delphiforums.com)

 

[Whiskey]

Welcome from Kennesaw GA!

The stator is probably the issue. If it were me, I wouldn't bother checking anything else until you get that, since you've already got it on order. Good luck.

 

[Diamond Dave]

you may be aware that 05/06 c90;s did have stator issues...when i got my 05 c90 in 2010 I asked my mechanic if I should replace the stator since the mc still had the original stator...he...suzuki service tech... told me he found the stator issues were running about 50/50 on the affected years...so he advised not to...shortly after the mc died...yep...stator...that occured at 15k...lost that mc in an accident,,,girl blew a stop sign ...replaced the totaled 05 c90 in 2013 with an 06 c90... again mc still had original stator...bought the mc with 8k on the dial,,,that stator lasted till 2018 with 54k on the dial...for a while I thought I was going to be ok with the original stator,,,learned the hard way to carry a spare stator with me when on a trip...place I had it towed to in NH ripped me off royally...is what it is...good luck finding the issue, may also want to check here...

Suzuki 1500LC / C90 Owners Group-Classic (delphiforums.com)

I should have done more research on the bike before buying it. Had I seen all the issues on the electrical I would have asked more questions and possibly had it inspected by a mechanic. I’m pretty solid with mechanical issues, electrical is a whole new animal.
Thanks, I’ll figure it out.

 

[Diamond Dave]

Welcome from Kennesaw GA!

The stator is probably the issue. If it were me, I wouldn't bother checking anything else until you get that, since you've already got it on order. Good luck.

Yeah, that’s what I’m thinking too. Once the new Stator is installed and it’s changing again I’m going to do this wiring mod,http://www.moccsplace.com/images/charging/VL1500_Charging_System_Wiring_Upgrades.pdf.
I’ll update as I work through the process.

 

[DCinCT]

hope its just the stator and the mod you are looking at should improve the system...aside from the stator issue, I will say my experiences with both c90's, the 05 I got at 15k and lost it with 65K,,,and my present 06, purchased with 8k and now over 80k, I have been very pleased with minimal issues, My last issue was the starter relay but rather inexpensive fix. I did need to install a GMan Bully when I purchased the 06, previous owner had w\swapped out the pipes to dualies, and failed to do the necessary mod to prevent unnecessary backfiring on the down shift. Again, Gman Bully took care of that. One nice feature of the c90's are no need for valve adjustments, they are self adjusting.

 

[Diamond Dave]

hope its just the stator and the mod you are looking at should improve the system...aside from the stator issue, I will say my experiences with both c90's, the 05 I got at 15k and lost it with 65K,,,and my present 06, purchased with 8k and now over 80k, I have been very pleased with minimal issues, My last issue was the starter relay but rather inexpensive fix. I did need to install a GMan Bully when I purchased the 06, previous owner had w\swapped out the pipes to dualies, and failed to do the necessary mod to prevent unnecessary backfiring on the down shift. Again, Gman Bully took care of that. One nice feature of the c90's are no need for valve adjustments, they are self adjusting.

Glad to hear. Funny you mention the backfiring issue. The previous owner put on Vance and Hines but I don't see any power commander on it. It backfires like crazy on the downshift. Kind of annoying and I'm sure that's not good for fuel economy. But I'm just guessing on that. So you like the Gman Bully? Can you send me the one you purchased? Thanks for your help and feedback.

 

[DCinCT]

GMan Motorcycle EFI Controller for Suzuki Boulevard C90, C90T, 2005-2011 (gmanindustries.com)

comes w/3 settings depending on your riding preference. also great customer service if you have any questions.

 

[Diamond Dave]

Quick update. The issue was the Stator. Check out the pic. The tricky part was adding wire to the Rectifier wires. The owner before me used these crimp connectors which are impossible to disconnect. I had to cut them out and extend the wires using wire caps. See the image of the connectors. To recap I installed a new (Rick's) Rectifier/Regulator and Stator. I now get 13.7 volts at idle and 14.7 at 5000 rpm. I believe the direct wire-to-wire connection from the stator to the rectifier helped bring the numbers to this level. Thanks for all the help on this. One additional benefit of changing the Stator, it fixed the oil leak coming from the stator case. The Stator replacement was pretty easy. One suggestion to anyone that will try this is to make sure to remove the shifter bolt and loosen the front and remove the back bolt of the footplate. This will give you plenty of room to work and access the bottom bolts. See Pic.

Now I'm going to ride the living Shiz out of this beast. Happy riding everyone.

Diamond D

 

[Whiskey]

Awesome! Thanks for the update and the tips.

 

[DCinCT]

glad to see thats all it was...my back up stator I carry with me when traveling is a Ricks Stator. Hope I never have to use it but if the situation arises, at least I won't get too badly ripped off. Now enjoy riding.

 

[davefzblvd]

The gsxr 600 and 750 had stator and regulator rectifier issuers from 2008 to 2010. I had to deal with it on my bike. Ot went bad around 11,000 miles. When the stator goes change them both as stator issues can destroy the reg/rect. The suzuki service manual has a very detailed way to check both. It sounds like you changed the regulator already so if you did not use it with the stator it should be okay. If you ran the bike with the old stator I would go through the testing. When I ordered the new stator and regulator through motosport.com they knew about the issues and sent me the updated oem versions. I would get updated oem version or Ricks. Ricks are reliable too.

 

[davefzblvd]

glad to see thats all it was...my back up stator I carry with me when traveling is a Ricks Stator. Hope I never have to use it but if the situation arises, at least I won't get too badly ripped off. Now enjoy riding.

You carry a backup stator! What other backup parts and tools do you ride with? That would make a good new thread.

 

[Diamond Dave]

The gsxr 600 and 750 had stator and regulator rectifier issuers from 2008 to 2010. I had to deal with it on my bike. Ot went bad around 11,000 miles. When the stator goes change them both as stator issues can destroy the reg/rect. The suzuki service manual has a very detailed way to check both. It sounds like you changed the regulator already so if you did not use it with the stator it should be okay. If you ran the bike with the old stator I would go through the testing. When I ordered the new stator and regulator through motosport.com they knew about the issues and sent me the updated oem versions. I would get updated oem version or Ricks. Ricks are reliable too.

Yes I installed the new rec then rode very few times since the bike was not charging at all. When I check the system at idle I’m getting 13.5 volts, 14.5 at rpm. The runs like a rocket now. Thanks for the feedback. The next item is the G-man upgrade. Take care of the backfiring issue from the Vance and Hines pipes.

 

[DCinCT]

with the history of the c90 stators, although supposedly improvements were made after the problems the 05/06 models had, one still can never be sure the problem won't occur again. and having had the unfortunate experience a few years back of having the stator go bad while vacationing in NH and then getting badly ripped off by a honda service dept, closet place to have it towed by AAA when I broke down, from then on, I always carry an extra stator when away from home. Aside from that. just tools, extra nuts & bolts, air inflator, tire repair kit, and a can of seafoam in case I pick up a bad load of gas. Also a safety vest to put on in driving on a day when it seems no one notices me.