Battery charge problem 2006 k6 DL1000

[Tomto]

Since I bought my 2006 V strom DL1000, I have not had a good charge going back to battery. Here's what I've done:
1. Replaced the regulator/rectifier
2. JB welded in all the magnets as they were loose
3. Had a local garage look at and fit a refurbished stator
Still the bike is not charging. I am left with considering buying an expensive rotor which are not easy to come by.
Any ideas? Also why if this problem is so widespread, have Suzuki or a third party not made a replacement?

Help please as frustration is kicking in...

[Graham62]

When I fitted a new R/R I I rewired it back to the battery just incase the wiring loom was at fault.

[Gert]

Any chance that a stator magnet may have been reversed when the magnets where glued?
Have you tested the stator resistance as per the service manual:   
section 7-8    under the heading   GENERATOR COIL RESISTANCE      extract:
     Tester knob indication: Resistance (ohms)
     Generator coil resistance: 0.2 - 0.5 ohms (Yellow - Yellow)
     infinity ohms (Yellow - Ground)
NOTE:  When making above test, it is not necessary to remove the generator

[kwackboy]

As Gert said ...

It's possible you've glued the magnets wrong, the polarities all have to be in the same direction.

Test the output of the stator buy setting your meter to high voltage (200v AC).
Unplug the stator from the regulator, start your bike and then test the output of all three phases (3 yellow wires) coming from the stator, each should be putting out around 40v+ @ 5k rpm.

Also, without your bike running you can check the stator is a good one by setting your meter to ohms (20k).
Again , Unplug the stator connection, put your negative meter wire to a good earth and then touch the live meter wire to each phase (3 yellow wires) , if any or the tests zero out , the stator has gone to earth,  it's no good.

[Tomto]

Quote removed

I have had it at the garage and the stator has been checked. I will double check the magnets when I get it back but I feel sure they all went in so that N met S as if they wanted to stick together. Is it possible I should have put them in the other way round though and would that make a difference?

[Tomto]

I pick the bike up tomorrow and if we ever get some decent weather, I will look at the magnets and maybe take them out and reverse the direction of polarity. Still making sure they all go the same way. I will consider the wiring loom as well and hope I can get it working properly. Still interested to know if there is another more modern rotor that would fit...

[Ianmc]

    Not sure if the wiring on the 1000 is similar to a 650, but I had the same problem on my old K9 650, have a look at the negative leads from the battery, mine had a heavy main lead to the engine as an earth, and also a smaller cable coming from the regulator to the battery negative with a connector half way.Mine had this connector disconnected although it still looked good, it had parted internally. I managed to solder it together and bingo, charging back to normal.