Regulator/Rectifier Troubles - Suzuki ATV Forum
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post #1 of 10 Old 06-21-2019, 02:58 AM Thread Starter
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Regulator/Rectifier Troubles

G'day everyone.
We have a Suzuki Quadmaster500 auto. Over the last week the battery on start up seemed to lag a little and I put it down to our cold winter here in Australia. Today there was a smell of burning or hot wires coming from it. I removed the seat to find smoke coming from the Regulator/Rectifier.
All connections to it were good, the battery connections were clean and tight and the earth from the battery to the engine chassis was also in good order. When I removed the Regulator/Rectifier it was hot and blown out on the back behind the heat sink (see photo). Is this something that happens in time with normal wear and tear or is this something that could have been prevented?

I thank you all for any advice or help you can give. Regards, Kevin.
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post #2 of 10 Old 06-21-2019, 10:33 AM
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Rectifiers/regulators do go on these quads. On the 300 KQs it seems to happen to some. Its not uncommon. Id replace the rectifier/regulator and go from there.


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2000 Suzuki King Quad 300 4x4
K&N Air Filter
2300 lbs Superwinch
Kenda Bear Claws (Rear 25X10-12) - (Front 24X9-11)
Differential Lock Mod
14,000 + km/s
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post #3 of 10 Old 06-21-2019, 10:46 AM Thread Starter
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Thanks ajl719.
My fear was replacing it and having it happen again due to an underlying problem. Ive found Rectifiers/regulators on ebay and they aren't cheap. I'm not sure if there are better ones out there? If anyone can recommend one I will be so grateful.

Thanks again ajl for your reply and kindness.
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post #4 of 10 Old 06-21-2019, 10:53 AM Thread Starter
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ajl719, I just read one of the threads where you've told someone else not to cheap it out.
I'll order an OME and do it right. Thanks mate.
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post #5 of 10 Old 06-21-2019, 12:04 PM
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Definitely buy a suzuki replacement and not china junk
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post #6 of 10 Old 06-21-2019, 03:47 PM
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Regulator/Rectifier Troubles

Yes, buy OEM replacement. Especially for anything electrical. And there could be an underlying problem. But without a working rectifier/regulator to confirm it was the issue, it would be hard to know if its the culprit or something else. Though it looks like it just burnt itself out.


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2000 Suzuki King Quad 300 4x4
K&N Air Filter
2300 lbs Superwinch
Kenda Bear Claws (Rear 25X10-12) - (Front 24X9-11)
Differential Lock Mod
14,000 + km/s

Last edited by ajl719; 06-21-2019 at 03:50 PM.
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post #7 of 10 Old 06-22-2019, 02:18 AM Thread Starter
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I've ordered a new OEM Rectifier/Regulator which set me back $320.00 AUD, they're not cheap. I've been told I can get it in 2 weeks because they're on order coming from overseas.
When it arrives and it's fitted I've organised to have the stator checked just to make sure everything is working the way it should.

This quad is a hard working farm bike and it's very rarely ridden at speed, which means there would be little to no breeze running over the Rec/Reg heat sink which is hidden beside the air box and the plastic cowling. I'm toying with the idea of moving the Rec/Reg forward to the front of the bike, maybe behind the thermo fan.

I'll let you know how I go with it all. If I do move the Rec/Reg I'll take pics and show its new location. This move might not work for everyone but our quad doesn't go through water or mud so it should stay clean and cooler.

Thanks guys for your help with this.
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File Type: jpg 22nd June 2019 (4).JPG (3.15 MB, 5 views)
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post #8 of 10 Old 06-22-2019, 01:31 PM
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FYI

If you relocate the rectifier....Be sure it is mounted to the frame on a flat spot at both mounting bolts as it uses the frame as part of the heat sink.....It may also use it as grounding connections but not sure on that one.

2002 King Quad 300
2001 King Quad 300
1997 King Quad 300
1997 quad Runner 250 2x4
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post #9 of 10 Old 06-22-2019, 11:21 PM Thread Starter
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Thanks TC,
The idea of a base plate of aluminium drilled with holes acting as a heat sink itself sounds good.
Nothing like a bit of over kill lol. Cheers.
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post #10 of 10 Old 08-11-2019, 06:44 PM Thread Starter
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G'day everyone, I fitted the new OEM Rec/Reg and had the stator checked and it was putting out the right specs.
The dealer I go to deals with a lot of farm or working quads. When I quizzed him about the life of the Rec/Reg and what makes them burn out he asked had our quad done a lot of weed spraying and was the electric spray pump powered by the quad battery? I told him it had and yes we have a connection to the battery to the electric spray motor. He went on to tell me its common for Rec/Regs to die in time doing this. The drain through the Rec?Reg is high and the quad being stationary isn't getting the cool air needed to cool the heat sink on the Rec/Reg. It all makes sense but I cant swear he's right. Anyway the quad is on the go again and working well. I hope this tread helps someone else out. Hooroo, Kevin.

BTW, I mounted the Rec/Reg in its original spot due to need for the quad ASAP for work. When I get the time I'll mount the Rec/Reg up near the radiator fan. This is just another job to do on the never ending list lol.
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