If I rewire a regulator wrongly?

[Hamish Carlson]

what will happen? It's a 1984 GSX400L. I'm trying to wire a kr150 rect/reg to it. The colours are all wrong, but I think I've figured out what wire does what, except for the kr150 reg (4 wire, gree, red, yellow yellow), I don't know what the earth wire is, could it possibly be the casing of it? If your replies say it wont work, I won't try it and get another reg with 5 wires (black red white blue yellow. current reg/rect that burned was 5 wire with one being earth.

[pete376403]

Go to Supercheap and buy a volt / ohm meter. Put the meter on Ohms, one probe on the body of the regulator, check each wire in turn till you get one with 0 ohms resistance - that will be the earth wire.

[Warr]

If you are still having problems give me a yell. I'll PM you my number

[skidMark]

what will happen? It's a 1984 GSX400L. I'm trying to wire a kr150 rect/reg to it. The colours are all wrong, but I think I've figured out what wire does what, except for the kr150 reg (4 wire, gree, red, yellow yellow), I don't know what the earth wire is, could it possibly be the casing of it? If your replies say it wont work, I won't try it and get another reg with 5 wires (black red white blue yellow. current reg/rect that burned was 5 wire with one being earth.

Itll kill us all.

[Katman]

The green will be the earth.

[Hamish Carlson]

but now its still not charging, the new rectifier isn't heating up or anything as I made an airflow system for it. Its a GN250 reg, so all the wires matched perfectly. Altenator is making power, as when I rev it up, the indicators go from not clicking to clicking on and off. Also when I rev her out to ~7000rpm, it cuts out intermittently. What would cause this as I've been trying to fix her for a month now, and she still wont run reliably!!

[Warr]

Sadly looks like the alternator is the source of your present troubles....

You are correct there should be no connection to ground in the alternator. Yours does...

Here is a wiring diagram of the GN alternator and showing the light switch which adds in the 3rd set of windings.
The other side of the switch then feeds back to the regulator to be rectified.
Not sure on your's which wire that would be. Perhaps the 'extra' one we talked about.

Here is the guy to contact for rewiring an alternator
Cairns Ken Electrical Services
11 Leonard Pl Dinsdale Hamilton
0-7-847 4233

[Hamish Carlson]

http://thegsresources.com/garage/gs_statorfaq.htm Yeah, from reading this I'd say the stator defonitly is rooted.

[Warr]

Couple of other places to try
SUZUKI, Motorcycle Dismantling
GSX400E 1986
GSX400X Impulse 1987
GSX400F 1981
Timaru Motorcycle Wreckers, 53 North Street, Timaru, Contact Grant, Phone & Fax 03-684-4355, Email: tmcw@xtra.co.nz

SUZUKI, Motorcycle Dismantling
GSX400
Manawatu Motorcycles, PO Box 2072, 32 Andrew Young Street, Palmerston North, Contact Paul De Lautour, Phone & Fax 06-357-7216.

[Hamish Carlson]

have ordered one from bazbikes, said he had a couple in stock, so sent a photo of stator with dimensions just to make sure I get the right one first time

[Warr]

Good news then. Hope it is a good price too.
I'm guessing that you have the stator out?? can you see any damage ?

And if it is this place, may as well give them a plug
Baz Bikes
Robinsons Road
Motueka
Upper Moutere R.D. 2

Phone or Fax 0-3-526 7175
or
send an email to
enquiries@bazbikes.co.nz

[Wired1]

what will happen? It's a 1984 GSX400L. I'm trying to wire a kr150 rect/reg to it. The colours are all wrong, but I think I've figured out what wire does what, except for the kr150 reg (4 wire, gree, red, yellow yellow), I don't know what the earth wire is, could it possibly be the casing of it? If your replies say it wont work, I won't try it and get another reg with 5 wires (black red white blue yellow. current reg/rect that burned was 5 wire with one being earth.

I've just been learning about this on my XT550. The regulator you have just bought is a single phase one so might not suit your bike as most bigger bikes seem to be three phase ones. The colours on the new one are yellow x 2 are the alternator input, red is positive output, and green is ground. You need to have the battery connected before you fire it up or else you might get a voltage surge and pop all your bulbs (been there done that).
Check your wiring diagram for your bike and see how many wires are coming from the alternator - if it's two then that should work, if it's three then it may work but might not have enough grunt to charge your battery as well as run the lights. A lot of bikes have a five wire regulator where the fifth wire is a reference point and can probably be ignored.

[Warr]

.........The colours on the new one are yellow x 2 are the alternator input, red is positive output, and green is ground. You need to have the battery connected before you fire it up or else you might get a voltage surge and pop all your bulbs (been there done that).
Check your wiring diagram for your bike and see how many wires are coming from the alternator - if it's two then that should work, if it's three then it may work but might not have enough grunt to charge your battery as well as run the lights. A lot of bikes have a five wire regulator where the fifth wire is a reference point and can probably be ignored.

I think you will find that the 3 phase ones have 3 yellow wires.
Hamish's alternator does have 3 wires . What he hasnt 100% determined is if the 3rd wire is a lighting only.

Being an earlier model it needs to be determine if the original configuration was 3 phase or if it just had another winding for the lights. Seems unlikely but not impossible.
What would help is a wiring diagram for his model/ or something close

[Hamish Carlson]

Got the stator rewound for $200 from a place in Tauranga, very good service. Put stator back in, connected everything up and now it's charging. HOWEVER, as I went to start up to auckland this morning I discovered yes its charging, but its getting up to 16V going to the battery (hooked a multimeter up on handlebars ). The regulator wasn't heating up to high temperatures either (one on it is off gn250). Also in 6th gear the engine started 'bottoming' and cutting out, might be related, might not. at 1500rmp its charging at 13.2 with lights on.

[davereid]

16v is a bit high, 14.8 is more normal.
Check all your earths, 16v will gradually boil your battery dry, so keep an eye on things. You may find that in normal daily running its actually OK.. not time to sell me the bike really really cheaply just yet.