GS450 headlight/electrical issue...

[posplayr]

Never seen one of those R/E's. there are two things that I know of that can cause overcharging. One is a 6 wire r/r where the sense wire is attached where there is voltage drop. That forces the r/r to output more current to bring the low point up to 14.5v;
The other is where the regulator is only regulating on one leg and the charging system puts out enough on two legs to overcharge the battery.
Do a quick test if you get a decent battery to confirm overcharging, but the get a different r/r and do the grounding recommendations.
Search for sh775 Polaris series r/r those are the best going right now.

[robertbarr]

Yeah, that thing just has 'Long Walk Home' written all over it.

Look into either the recent FET (009 or 012) or the series regulators that we've been blabbing about relentlessly. There's a fairly current thread about the connector kits for them - from deluxe to homebrew, both probably just fine.

That's certainly a reasonably well-executed jury-rig for securing the H4 module, but it sure would be nice to have the spring clip that belongs there. I have one somewhere for the rectangular light from the Nighthawk in my sig -- it's a matter of finding it. I also have a known-good 009 available free + shipping + buyer digs out the existing RTV sealant.

Let me do some hunting.

[posplayr]

Sorry Robert , the fh009/012 fet r/r are still shunt and should not even be considered unless you just can not find an sh775 series unit

[schmitty78]

Yeah, that thing just has 'Long Walk Home' written all over it.

Look into either the recent FET (009 or 012) or the series regulators that we've been blabbing about relentlessly. There's a fairly current thread about the connector kits for them - from deluxe to homebrew, both probably just fine.

That's certainly a reasonably well-executed jury-rig for securing the H4 module, but it sure would be nice to have the spring clip that belongs there. I have one somewhere for the rectangular light from the Nighthawk in my sig -- it's a matter of finding it. I also have a known-good 009 available free + shipping + buyer digs out the existing RTV sealant.

Let me do some hunting.

I have the whole head lamp unit/assembly on order, but thanks! I took the battery back to the store I bought it from, and they just did a warranty swap. Now it will have to charge overnight before I can dig much further into this. So, I'm guessing it's safe to say, I might as well replace the r/r? I ran across a thread the other day mentioning the Electrosport ESR100, and how it is a high-quality product. Any objections to this particular one??

[koolaid_kid]

Absolutely replace the r/r before running the bike again.
As posplayr suggested, find a sh775 unit and use that.
Here is a thread discussing it.

[pete]

Man I thought I got a good deal locating my SH532 here for about $60 posted to my door... could've had a series for just the extra cost of shipping! Then again that would've been weeks without the bike too...

Cheers Jim, I know what R/R I'm looking for next time!

[schmitty78]

So has anyone found a definite cheap source with good shipping options, in the US, for the SH775?? I'm strongly considering getting this with new wiring and connectors from easternbeaver.com, and a new stator from ElectroSport, just so I have a new, known starting basis. I'm getting tired of riding for a week or 2, then being down again. Hindsight is 20/20 they say? I should've had more motivation and done all this back in the winter! Oh well, lesson learned!

[schmitty78]

SH775, ElectroSport stator, wiring and connector are ordered. Now to find time and test out the wiring to make sure I didn't have a problem that might've drawn down the voltage on my last battery.....

I'll look forward to figuring out the best place to mount the new r/r.....should be interesting.

[pete]

Just make sure it's somewhere it can get good air flow and you should be good to go.

I like where the Triumphs mount them... under the headlight... not sure how easy it would be to do that on our 450's though...

[schmitty78]

Just make sure it's somewhere it can get good air flow and you should be good to go.

I like where the Triumphs mount them... under the headlight... not sure how easy it would be to do that on our 450's though...

Under the headlight huh? That is an interesting proposition. Don't think I'm gonna try that just yet though...too much extra wiring for now. Hopefully the r/r will be here tomorrow, and I can play around with some ideas. Got the stator in today...man it's a tease not having all the other parts here yet! I'm ready to get this upgrade over with and get back to riding!

[pete]

That gets very frustrating... hopefully not too long a wait though...

[schmitty78]

R/R looks like it won't be here until Monday. I ordered a jacket that I was real excited about getting today...well I got it, to find out it's one size too big. Not a great day here... :/

[schmitty78]

So, I have most of the parts I need to begin the upgrade to the SH775 r/r. Still waiting on the gasket so I can do the ElectroSport stator swap. I've been trying to search, with no real results, for a thread on here showing the recommended wiring changes. Can anyone point me to one??

I have begun some basic repairs to some of the shoddy wiring "fixes" done by POs. Here's one of the or/wh wire coming from the igniter, soldered, and ready for liquid electrical tape & shrink tubing. The original splice was just a regular red butt connector, and I could spin the thing around the wires without them moving.



And here's one that I'm trying to figure out what to do with. Since I have the Easternbeaver kit with fused positive wire, I'm wondering if this red wire with crappy inline fuse spliced to it can be removed?



Finally, here's the new SH775 goodness with Easternbeaver wiring kit and connectors.

[pete]

Glad to see you tackling that wiring! PO's do make a mess of things...

I got your PM... my wiring was already setup for the 6 wire R/R when I got my bike way back in '98, so I didn't have to tackle that myself.

Note all the colours below are from my '82 wiring diagram.

It looks like what they did was pretty simple. The red/white wire from the R/R goes to the headlight and comes back as green/white to one leg of the stator.

This circuit is bypassed so that leg goes straight to the R/R, along with the yellow and blue/yellow.

Other than that, the red remains the 12v output, and the main fuse is between the battery and the R/R.

The sense wire on my R/R is hooked into the switched orange wire, but I'm not sure at which part of the circuit.

And of course black/white continues to be ground.

Hope that helps!

[schmitty78]

Glad to see you tackling that wiring! PO's do make a mess of things...

I got your PM... my wiring was already setup for the 6 wire R/R when I got my bike way back in '98, so I didn't have to tackle that myself.

Note all the colours below are from my '82 wiring diagram.

It looks like what they did was pretty simple. The red/white wire from the R/R goes to the headlight and comes back as green/white to one leg of the stator.

This circuit is bypassed so that leg goes straight to the R/R, along with the yellow and blue/yellow.

Other than that, the red remains the 12v output, and the main fuse is between the battery and the R/R.

The sense wire on my R/R is hooked into the switched orange wire, but I'm not sure at which part of the circuit.

And of course black/white continues to be ground.

Hope that helps!

Pete,
Your reply helped some, but my dilemma here, is to figure out what to do (or how to re-wire) the wiring I no longer have direct connections to. The new ElectroSport stator has 3 wires: blue/white, yellow, and green/white. I know these three will go directly to the new SH775 r/r. From there, the r/r has a 35A (not sure of this fuse size) inline fused positive (red) wire which will go directly to the (+) battery terminal, and of course the negative wire that will go directly to the (-) battery terminal.

So, I will have 3 wires left over. The white/green wire came out of the old stator, and connected directly to a white green, that runs to the 'Lighting Switch' (I verified in my manual's wiring diagram), and as you stated, comes back to the r/r on the white/red. What do you mean by the circuit is bypassed? What becomes of the white/green and white/red wires in the wiring harness?

The last is the red 12V output. The old r/r had a red wire that connected to the red wire in the harness, which had another red, fused wire pigtailed to it, that connected to a red lead from the (+) battery cable. That is the wire that the PO had spliced in a thinner gauge yellow wire with crappy inline fuse, in the picture I previously posted. My question here is, since I have a main fuse between the r/r and the battery, can I just connect the main red wire from the wiring harness directly to the red lead from the OEM (+) battery cable, removing the 'pigtailed' fused wire? Or does the 12V output from the (+) battery terminal to the wiring harness need to also be fused?

Any further help Pete, or from anyone, is much appreciated!