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Thread: changing over original Suzuki R/R to SH775

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    Default changing over original Suzuki R/R to SH775

    I'm now to this GS forum so hope I'm not repeating earlier posts. However I couldn't find my specific question being answered.

    I have a 1978 GS1000E with a burned out stator and rectifier. This is the second time I've had to replace the rectifier and now the stator is also damaged. On this model GS the rectifier and voltage regulator are two separate parts.

    After reading through the forum entries it looks like I might solve my charging problems by converting to a SH775 regulator rectifier from Polaris (part number 4012941). As I understand it, this SH775 would replace both the rectifier and regulator on my GS1000. Please correct me if I'm wrong.

    My main question is how is the new SH775 regulator rectifier wired to replace the OEM parts? I can't find any forum entries that show how this is done. Where do the wires from the stator get connected on the SH775, and which are the output wires on the SH775 that would be wired where the old voltage regulator wires were connected?

    Thanks for any help anyone can provide. If there is a previous forum entry that covers this already please provide me link.

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    Bob T.

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    and.... somewhere, can find the part number for a truimph wiring harness that has connectors that fit the sh775. Is something like 12 bucks.

    Had 850G for 14 years. Now have GK since 2005.
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    Triumph harness part number is T2500676.

    Baatfam gave you a link to wiring diagram. It's very easy to upgrade from a combined unit from later years, but your two-piece setup isn't much harder.

    Your three stator output wires go directly to the three inputs of the 775. Easy enough, it's pretty much like your current setup.

    Your current setup then goes from the rectifier to the regulator. Ignore those connections, think of the two units as a single piece. After the regulator, there is an output line that feeds the bike. THAT is the one that will connect to the output of the 775.

    It is common practice here to have a single point where all your ground wires come together, including the R/R ground. The battery will also be connected there, but for simplicity, do NOT make the battery post your single-point ground.

    .

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    Post #11 in this thread has a link to the Triumph connector. I was helping this guy do the same thing you’re doing. Problem was, I think, that the a previous owner had gotten creative with the wiring and this guy just couldn’t sort it for some reason, gave up, and put stuff back the way it was. I know that’s not the answer.

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    Quote Originally Posted by Utah Bob View Post
    I'm now to this GS forum so hope I'm not repeating earlier posts. However I couldn't find my specific question being answered.

    I have a 1978 GS1000E with a burned out stator and rectifier. This is the second time I've had to replace the rectifier and now the stator is also damaged. On this model GS the rectifier and voltage regulator are two separate parts.

    After reading through the forum entries it looks like I might solve my charging problems by converting to a SH775 regulator rectifier from Polaris (part number 4012941). As I understand it, this SH775 would replace both the rectifier and regulator on my GS1000. Please correct me if I'm wrong.

    My main question is how is the new SH775 regulator rectifier wired to replace the OEM parts? I can't find any forum entries that show how this is done. Where do the wires from the stator get connected on the SH775, and which are the output wires on the SH775 that would be wired where the old voltage regulator wires were connected?

    Thanks for any help anyone can provide. If there is a previous forum entry that covers this already please provide me link.
    PM me an email for drawings.
    Read about Charging Quick Test GS Charging Health GS Stator

    "The smallest giant of mankind, is he who stands on the shoulders of a larger giant who himself stands on the shoulders of yet a larger giant, and therefore sees the most light from GOD." Posplayr 2017 adapted from : Bernard of Chartres


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    Thanks to each and all for your guidance and suggestions on doing this rewire from factory a R/R to a SH775 system. I was concerned how I was going to make the connections to the SH775 and the Triumph wiring harness looks like it answers that issue. I'm ordering the parts and will install it all upon receipt of them. Hopefully all goes smoothly, but I'll be back on the forum with questions if anything comes up.

    Thanks again,
    Utah Bob

  8. #8
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    I finally received all the parts to do the upgrade to the SH775 system and installed the new stator but have run into a little confusion. When I removed the old stator it was indeed quite badly fried. But what is confusing is that two of the three wires coming from the old stator to the rectifier and regulator (remember, on my 1978 GS1000E the rectifier and regulator are separate units) split into two before connecting to the rectifier and regulator. These wires, the W/BL and the Y both split and one branch goes to the rectifier and the other to the regulator. Do I just twist these together and connect them to the input of the SH775?

    The third wire from the stator, the G/W doesn't go the rectifier or regulator but directly to the light switch. I read why this was in other places on this forum, but do I now connect that G/W wire to the third connection on the SH775? I'm concerned that it won't then go through the light switch and the headlamp won't work. Is this not an issue? I tried to figure it out looking at the wiring diagram for the GS1000E but got lost in all of the connections.

    Also, this wire was unregulated so it must have been at about 75 volts AC. Will the headlight work properly if this wire now goes through the SH775 and thus runs at a lower voltage? I assume it will since no one has said otherwise on this conversion to the SH775, but I'm curious about why the headlight will now work at the lower voltage.

    Thanks for any assistance and insights you can provide.

    Also, a side note. It was a bugger trying to get the 42 year old bolts off of the generator. The first three phillips head bolts were getting stripped, so I finally bought a hammer driver and it worked like a charm, even on the damaged bolts. Hope this might help someone else facing this problem with stuck bolts.

  9. #9
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    To avoid numerous quotes, cuts and replies, I am simply going to re-post your last post and insert my replies.

    I finally received all the parts to do the upgrade to the SH775 system and installed the new stator but have run into a little confusion. When I removed the old stator it was indeed quite badly fried. But what is confusing is that two of the three wires coming from the old stator to the rectifier and regulator (remember, on my 1978 GS1000E the rectifier and regulator are separate units) split into two before connecting to the rectifier and regulator. These wires, the W/BL and the Y both split and one branch goes to the rectifier and the other to the regulator. Do I just twist these together and connect them to the input of the SH775?
    If you have installed a new stator, the wires should not be split, so there is nothing to twist. However, if, by some chance, you DO have split wires, you can twist them together or cut off the extra.

    The third wire from the stator, the G/W doesn't go the rectifier or regulator but directly to the light switch. I read why this was in other places on this forum, but do I now connect that G/W wire to the third connection on the SH775? I'm concerned that it won't then go through the light switch and the headlamp won't work. Is this not an issue? I tried to figure it out looking at the wiring diagram for the GS1000E but got lost in all of the connections.
    If you "read why this was" in other parts of the forum, you must have only read part of it.
    The headlight switch has TWO sets of contacts. One of them is for the 12 volts DC from the battery to the headlight. The other one is the AC voltage from the third leg of the stator. Removing the feed wire from that second set of contacts has nothing to do with whether the headlight works or not. Removing that wire eliminates multiple connection points that each can be a possible corrosion point.


    Also, this wire was unregulated so it must have been at about 75 volts AC. Will the headlight work properly if this wire now goes through the SH775 and thus runs at a lower voltage? I assume it will since no one has said otherwise on this conversion to the SH775, but I'm curious about why the headlight will now work at the lower voltage.
    Stop assuming and read my previous paragraph.


    Also, a side note. It was a bugger trying to get the 42 year old bolts off of the generator. The first three phillips head bolts were getting stripped, so I finally bought a hammer driver and it worked like a charm, even on the damaged bolts. Hope this might help someone else facing this problem with stuck bolts.
    Hopefully you have learned that the impact driver should be your FIRST tool, not a rescue tool.
    Use it FIRST to prevent damage to the fasteners.

    .

    mine: 2000 Honda GoldWing GL1500SE and 1980 GS850G'K' "Junior"
    hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
    #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
    #2 son: 1980 GS1000G
    Family Portrait
    Siblings and Spouses
    Mom's first ride
    Want a copy of my valve adjust spreadsheet for your 2-valve per cylinder engine? Send me an e-mail request (not a PM)
    (Click on my username in the upper-left corner for e-mail info.)

  10. #10
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    Steve, you missed that those aren't Phillips screws, but JIS
    The proper tool is helpful
    Put some purple threadlocker on the bolts when you install
    1978 GS 1000 (since new)
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