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Old 11 Dec 2011
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charging problem on DRZ 400

Hi Guys,

I just bought for cheap a 2006 DRZ400 SM, thinking about converting it into an adventure bike.

The battery was dead and there was a charging problem according to the seller, because he kept changing batteries every year.

I tried it with another battery (a little bit smaller, but new one), and on idle, i have approx 14.05V, when I put more revs it goes down to 13.8V. I suppose it's not normal. Is it?

I googled and found out about the modificating where you cut the red and black wires from the regulator and replace then with 2 cables that goes directly on the battery, but before doing that, I wanted to ask first about my problem.

On thumpertalks, I red that you can check if the alternator is working correctly by unplugging the connector with the 3 yellow cables, and mesuring tension between them. The guy said that you should get 90V AC.

With idle, I only got about 30-32V AC, revving the engine it goes up to 80V.

Can someone tell me if it's normal?

Thanks in advance for your help.
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Old 13 Dec 2011
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I found the answer myself. I post it here, maybe it can help somebody else:

the guy on thumper talks says:

Use a volt meter at the battery. This test needs to be done with a good and fully charged battery. Motor off key off - you should have 12.8 or more volts. Key on, lights on, motor off - around 12 volts is good. Motor running at idle - above 13 volts is good. High idle to around 3000 rpm - 14 to 14.5 volts is what you want to see. Suzuki says 13.5 is OK but that will not keep a battery charged. Many DRZ's will show the highest voltage at idle and the voltage drops as the rpm goes up. That is ok if it is above 14 volts. It is not really dropping but your test meter thinks so.


Charging system diagnoses Plus the "Free Power MOD" - ThumperTalk
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Old 13 Dec 2011
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Join Date: Oct 2011
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Regulator connector

We had a problem on one of our DRZs and it was the regulator connector. The free power mod from Thumpertalk corrected it. At first I thought the regulator/rectifiier had gone, but it turned out just to be the connector. I gather people have spent ages chasing this problem, because the connection can get worse when it gets hot.

Sounds like you've already worked out the answer, but if you do have trouble start with that connector!
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Old 21 Dec 2011
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I own two of them and never had this problem...; i must say that every time to time I just plug in my charger when the bike's at home for a few days... just to be sure... Mounted a double 12V in front, near the ignition switch, just had to relocate a few things and everything works fine... I'll post a picture later.
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Old 1 Feb 2012
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New battery every year on a DRZ does not imply a charging problem. Flat battery after a day's ride would indicate a charging problem. DRZ batteries are marginal, but given that most people would like the DRZ to be lighter, we only have ourselves (the buying public) to blame for stuff like this. Fit a new battery and you've got the makings of a great adv bike...

(Though you should have just bought mine instead... http://www.horizonsunlimited.com/hub...ding-drz-61605)
'02 Africa Twin (sold), GSX-R 1000 K5 (sold), '97 TL1000S, '08 DRZ400 SM/S, '92 CRM250
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