Suzuki TS 185 electrical issues

[maxim]

Hi There,

First time user and very impressed with the site! Hope you can help me with some electrical issues I have with my TS 185 ER.. It's a 1991 model and no indicators were working when I purchased it so I tried to re-wire the indicators, but have the following issues:

I believe the indicators and tail brake light only should work of the battery and not the coil (headlight and tail light) as they are on different wiring diagrams - is this tight?

So my issue is the indicators and brake light gets brighter as I rev the bike and the indicators goes in a constant on mode (no flashing) which indicates that there must be a feed into the headlight and tail light system and runs my battery dry after 10 - 20 min.. - could this happen?

Does anyone have a wiring diagram or point me in the right direction as I'm all out of idea's and lack of knowledge of working it out?

Appreciate your help!

[jcarlin123]

Hi Maxim. It sounds as though your battery is overcharging, or as you say, the accessories are getting their power straight from the stator plate. To make sure, turn the key to ON but don't start the bike. See if your horn or indicators work with the bike not running. If they do then they're getting their power from the battery - it's just overcharging. My ts is a bit similar. The indicators speed up a bit if i've been riding around at high rpm. Unfortunately, only the headlight/tail light voltage is regulated on these bikes. You may want to check that the correct battery is in there though. If it's the wrong type then it will overcharge.

[maxim]

Thanks for the reply! Your are correct, the indicators and horn work with the key in the ON position (motor not running), but the battery was ordered from the recommended Suzuki parts catalog about 3 months ago... Maybe it's a faulty battery. The bike did stand for 4 weeks without use, but I didn't think that that should damage the battery.

The current battery after full charge does not old charge for 5min while the indicators are on (motor not running), so definitely a damaged battery, I just hope that the current wiring did not cause the battery to fail/damage

I'll change the battery this weekend and see if that makes a difference.

Thanks again!

[jcarlin123]

It might just be a feature of the 6v system? Mine does overcharge but it's not too bad. Perhaps a second voltage regulator could be installed on the battery circuit, as close to the battery as possible. That way, everything that runs off the battery will get exactly 6v.

[jcarlin123]

Here's a video where you can see that my flasher relay is getting a bit too much juice YouTube - 1982 Suzuki TS185

[maxim]

Wow, good looking bike, in top condition!! Your indicators is a hell of a lot brighter than mine, did you change them to LED? I replaced the battery yesterday and the indicators do seem to work better (battery holding charge), but I'm sure my flasher unit is the wrong one as it flashes very inconsistent, even with the motor not running..

Any other idea's?

cheers and thanks for the help!

[jcarlin123]

I'm using 6v bayonet bulbs in my indicators. I have an idea they're a higher wattage bulb than stock. I don't know what the go is with flasher relays. There might be some that require more/less voltage/current?

[hank85713]

not to hijack your theread I just got a clymers yesterday so I can maybe scan the schematic gfor you. Question, You said you have a parts bike, I need a carburetor for a 1974 TS 185. Do you have one? Willing to sell or trade?

Know where I can find one, anyone Have no luck with ebay.

Hank

[maxim]

Ok, so I installed a new battery and checked all the wiring for a bad earth etc, but the indicators work, just very very dim/weak. I did however see that there is no "rectifier" connected.

So, 2 questions: Can no rectifier present cause the indicators to get current, but not enough to light up as it should?

and: Do I have to look at installing a new "voltage regulator" ?

Thanks for your help!

[jcarlin123]

Maxim, the rectifier is needed to convert the AC current coming from the stator plate into DC current that will in turn charge the battery. If there is no rectifier, the battery will not charge, and your indicators will be dim. The regulator just caps the voltage off at 6v. If the regulator is faulty then your headlight will blow bulbs due to excessive voltage.

[maxim]

Ok, so I'm some what of an idiot... I did find the rectifier, but it's a lot smaller than pictures of the standard Suzuki TS 185 rectifiers, around 2 cm x 2 cm x 1 cm and it is connected to the "RED and WHITE WITH RED STRIPE" wires next to the battery just hanging loose (not mounted).

The battery does charge a bit when the motor is running, but runs out of umph very quick if the indicators are user when the motor is "off" (5 min)

Does this perhaps sound like a faulty or non correct rectifier?

Cheers mate and thanks for dealing with my stupid questions!

[jcarlin123]

I wouldn't be too concerned that the battery only lasts 5 minutes when the engine isn't running. Because it's a 6v small mA-h battery 5 minutes is probably all you'll get out of a good one. If the battery has really had it, then it will go flat overnight. If it lasts 24hrs i'd say it's alright.