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How To Wire a Motorcycle Series, Episode 3: Regulator Rectifiers Explained // Revival Tech Talk

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Anybody done this? Any body done this swap? Their plug goes like this. Where to hook to? I see same color wires where rectifier plugged into?? Im lost. Thinking about sending back,taking loss on shipping unless I can get some help Last edit: by perrykz I got one from them.

Fried my stator when it shorted. Z1b Z1b Opinions expressed by me do not reflect those of the the staff or members kzrider. Last edit: by SWest. I started a thread on it. Steve kzrider.

how to wire a regulator rectifier

Hi Guys, What should the voltage be at the battery with a KZ be? Mine is around I Tested my stator and it is good. The fear is running through me now. Hey SWestLog in or Join. Adventure Rider. LexLeroyAug 23, Painting and wiring is done. Here's the inside of the battery box, above, showing the new wiring and the fuse holder. Not good, particularly since this is a clean, low-mileage bike.

Things will only get worse with age, and I've seen pictures of these plugs in a melted state. I also clipped the 3-pin stator wire plug out of the circuit and soldered the wires together.

Tell me what you think. BeezerAug 23, HighFructoseAug 24, Oh my god i just had de ja vu reading this. Joined: Oct 15, Oddometer: 4, Location: idaho. It is said to run cooler, and be something that can be counted on to last.

I don't understand how it works. This bike has a permanent magnet rotor. How does it dispose of excess 'juice'? I don't see how, unless I am mistaken about the permanent magnets on the rotor. I can understand if the bike is not converting the alternator output to heat. ADV Sponsors. LukeJan 3, BeezerJan 3, CycleDoc59Jan 4, The wire directly to the battery is a good idea. One was the Aprilia Futura. The regulator puts out proper voltage, but never makes it to the battery A small jumper wire fixed it.

I use dielectric grease on every connector I can find, sealed or not. My expert explained that it opens the stator coils many times per second.This article is made due to many queries after the post about DeadBug Prototyping, so I've decided to make a whole instructable to explain how the motorcycle regulator relay works and how to make it.

It all started with the my friend, who have asked me to resolve the problem with Voltage Regulator on Honda X4 urgently.

how to wire a regulator rectifier

To know if it fits you have to look at the generic regulator, if it has one or two red, one or two black and three "other-colored" wires pink, brown etc.

In Honda X4 phase wires and plus-minus wires are separated into two power connectors one has three terminals, the other - four. So, let's begin.

There are motorcycles with automotive-type generators, but there are only few of them. Here I'd like to digress on the subject of "what is current, voltage, and a voltage regulator. Let's not dig into details now, it is just important to understand the main thing - an electric current has many parameters, but we need two most important of them - current and voltage.

The current is measured in amperes, and the voltage is measured in volts.

how to wire a regulator rectifier

To understand what it is, imagine that your wire is the channel, and the current - water flowing over it. So the current is water flow rate, and the voltage - water level in the channel. For further understanding of the text that's enough. We won't bother about rectifiers - a diode is a diode captain obvious was here. The objective of any voltage regulator - to receive a voltage and lower it to the certain desired level and hold it at that level.

The operating principles of the stabilizers are divided into impulse, linear and shunt. The shunt stabilizer makes excess voltage "bypass the consumer". The simplest shunt regulator is assembled from two parts - the resistor and zener diode. Zener diode, it is such a funny thing that when the voltage is less than needed, he zenner diode or ZD pretends absent ie, allegedly ragged wireand when the voltage is more than you need, he pretends to be a wire ie starts to freely conduct current.

Imagine valve with spring, that's the same principle. It works like this. When the voltage is less than you need, a zener diode does not conduct current, all the current goes to the consumer. Water flow is low, the valve is closed.

What Can Cause a Regulator Rectifier to Go Bad?

When voltage somehow is increased and becomes more than necessary, zener diode begins to conduct, and all superfluous voltage "falls" bypassing the consumer through the zener diode to the ground. Water flow is high, the valve is opened and pouring out the excess water. Thus, our power, our "water level" all time stays approximately the same value.

how to wire a regulator rectifier

Everything seems be fine, but there is no zener diode for high currents. This valve can only be a small diameter. Therefore, to make a stabilizer for high-current with the use of zener diode only is impossible.Bad Behavior has blocked access attempts in the last 7 days.

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Regulator/rectifier Conversion

Please login or register. Foyil Full Member Posts: Hi All, First and foremost I'd like to come clean and admit, I'm a total idiot when it comes to electrical issues.

Now that that's out of the way It would be a HUGE help! Thanks for the heads up just wasn't sure exactly which units to remove terrible. If you got that exact rectifier you pictured it won't be plug and play. On the 78F there's a thirdgreen ,wire with the black and white. I read somewhere that there is a way to plug this one ,with only 2 wirebut I don't know how.

My heroes had the heart to live their lives out on a limb And all I remember is thinking' I wanna be like them. CBF Quote from: Foyil on July 30,am. Hey Rick, That's just a generic pic I found on their site, the one I have might have the third plug but I forget, I wont be certain until I get home tonight.

Quote from: goldarrow on July 30,am. Posts: 19, I refuse While I applaud your willingness to replace defective components, I'll bet you dollars to donuts that these purchases may not solve your problem. Electrical is not difficult, though it can be intimidating if you are unfamiliar with it.

You need to test and diagnose your electrical system, so that when you install these new components, they work and they don't get damaged by existing faulty electrical connections. If you'd like to evaluate your existing system, so that you correct or replace the actually damaged component, let us know. Throwing money and parts at a problem is not likely to solve your issues efficiently.

Cal, thanks for the input. I agree it may not solve it but at the moment the game plan is to replace everything with newer components for peace of mind. That being said, what do you think a charging issue could be?

I was originally told the rectifier might be the problem so I am starting there. What else do you think? I also may think it's my battery to be honest so I just ordered a new Shorai 8-cell so I can cross that off the list we'll see when it comes in. Thanks again. Can you provide some details of what "charging problem" you actually have?

I'm not trying to be prickish at all, but some specific information is necessary.

2 Phase 5 Wire Regulator Rectifier Wiring Diagram

Until then it's running on the battery. Have you tested the voltage at the battery?These instructions cover most of the Honda singles and twins from and earlier. Other makes may require different modifications or have different wire colors.

This part replaces both the stock rectifier and regulator, those parts must be removed. To get higher constant AC voltage, permanently join both halves of the stator rather than having the switch at the handlebars or the switch on the headlight on some models turn on the extra current when the lights are on. This works on all of the and Honda twins.

If you choose to do this mod we strongly recommend connecting the regulator rectifier directly to the wires coming from the stator.

Tape up any unused stock connectors. Pre-Installation: Isolate the charging issue before ordering parts. Confirm your model has a single phase charging system. Check that the alternator is putting out the proper amount of AC current and all the connections are clean and making proper contact. Battery must be fully charged and in top working condition. Recommended Wiring Modification: To get higher constant AC voltage, permanently join both halves of the stator rather than having the switch at the handlebars or the switch on the headlight on some models turn on the extra current when the lights are on.

Not all models have regulators. Plastic connector plugs right in where original rectifier was. Mount new part where the old rectifier or regulator was. The casing does not need to be grounded. If the connector on the harness is different use the included parts to replace the stock connector. Use included wire with eye terminal to ground out the green wire on the regulator rectifier.

Make sure to find a solid ground.The article provides a detailed explanation regarding the various voltage regulator wiring configurations used in motorcycles. The article was submitted by Mr.

After working on different voltage regulators, I feel to share my findings on your blog so that other people may also get benefit.

Please insert the diagrams appropriately in the article. I will update further by providing examples of each type. Motorcycles are usually equipped with permanent magnet AC generators. The magnitude of the voltage produced by these generators depends upon the RPM of the engine. Despite these generators are specifically designed to produce about VAC at high RPMs, they do require a voltage regulator to provide a safe voltage for battery charging and for the electrical system.

These generators could have single-phase or a three-phase winding. No matter the winding is single-phase or three-phase; all voltage regulator units have two parts i. Rectifier Section and Voltage Regulator Section. Here, we will only discuss various types of voltage regulators and not their internal circuits. Since the incandescent bulbs work well on AC voltage, there is no rectifier section in this type of regulator.

The circuit inside the unit regulates the AC voltage coming from the generator to This regulator is basically an AC voltage regulator. In this system, we see that one end of the winding is grounded to the chassis of the bike, which is connected to the negative terminal of the battery. The other end of the winding supplies AC voltage to the rectifier section which converts it to DC voltage. Then it enters the Regulator section which maintains the output to an ideal In this system, both the ends of the winding go to the Rectifier section which converts AC to DC voltage and then the Regulator section regulates to In this system, the stator has dual windings.

One supplies power for charging the battery and for the electrical system.