'78 GS550 Rewire

[KJL316]

So far I have replaced the stator; the Rectifier and Regulator were also replaced with a Compufire unit.
But a lot of insulation is in rough shape so I am rewiring it as well as upgrading slightly by changing the turn signals into parking lights as well for increased visibility.
But a few questions:
1. In the wiring diagram, there is a box just below the battery with the Y/R, G/R, B/W and Orange wires leading to it, what is it? And where does the other end of the G/R wire go?
2. The W/R wire feeds from the Rectifier to the Lighting Switch and then the W/G leads back, is there a reason for this?


Any help or suggestions would be greatly appreciated!

 

[Nessism]

1. Not sure
2. That is the infamous stator loop. One leg of the stator power goes through the headlamp switch and stops there unless the headlamp is turned on. For bikes with headlamps that re always on, the loop is completely useless. Just wasted wire...and extra resistance. The extra run of wire for this loop often overheats, taking out the main harness in the process. This is why you should always rewire the charging system when installing a series R/R and bypass all that junk.

 

[KJL316]

Thank you for your reply. Just to make sure I understand, eliminate that loop and connect the 3 wires from the stator directly to the Regulator/Rectifier?

 

[Nessism]

Just to make sure I understand, eliminate that loop and connect the 3 wires from the stator directly to the Regulator/Rectifier?

Always....

 

[hannibal]

The first question: those are empty connections. The wires end in a connector without a mate.

Not sure why they did that. Maybe for future changes. The orange and BW are switch power and ground respectively and the YR runs to the big connector in the headlight bucket that feeds the gauge cluster. The GR wire just ends in another empty connector.

 

[hannibal]

The first question: those are empty connections. The wires end in a connector without a mate.

Not sure why they did that. Maybe for future changes. The orange and BW are switched power and ground respectively and the YR runs to an empty spot in the big connector in the headlight bucket that feeds the gauge cluster. The GR wire just ends in another empty connector.