Anybody know if it's possible to upgrade the generator on the GS500?  the stock generator is 225 watts (theoretically), and that doesn't leave a lot of room for extras (heated grips, clothing, Ham Radio, etc.

... refridgerators, coffee makers, computers, color TVs...


There are several aftermarket/replacement coil companies that claim higher outputs.  

The problem is that, as we all know, Suzuki uses the absolute cheapest, minimal materials they can get away with, especally its electrical systems.  Increasing the amperage of the generator may do bad things to the wiring, voltage regulator, and ignition.

How would you know when you've bumped into the capacity limit?  Rev to 5k, check voltage, then turn on all your goodies and see if voltage drops?

I'm sorry I can't help you with the upgrade question, but I may be able to provide some info that makes the OEM generator even worse than you think it is.

In the OEM Suzuki GS500 shop manual for the 98/99 model the max. generator output is rated at approx. 200W at 5,000 rpm.

Bob

Quote from: rcepluchthe max. generator output is rated at approx. 200W at 5,000 rpm.

...and how many watts are needed for the ignition system?  
I was thinking of adding a pair of driving lights, mostly for visibility in traffic, but that sounds like I might only be able to fire them up on the expressway (where I'd need them least).

You don't get something for nothing.  A higher capacity generator will draw more power from the motor, since the greater the current it generates, the more it will act like a brake on the crank.

I don't think you are going to notice the extra power that is drawn away from the engine. Max. is 200W, the engine can deliver 34000 W.

If you want to upgrade the generator, consider upgrading the regulator/rectifier also. I noticed that above 4500 rpm the amps go down.
I think that the regulator can't deliver lots of amps when it has to regulate the voltage too much. (the higher the rpms, the higher the voltage that comes from the generator).

I noticed this because I had heated grips and they would be the hottest at 4000 rpm. they cooled down a bit when idling and they cooled down a lot when you were in the high rpms.  (It wasn't because of the higher speed, I tested that by riding  the same speed a gear lower than usual. The temp. of the grips still got down.