Suzuki Regulator question

It appears my regulator has died in my 82 GSX1100EZ. My bike has a 5 wire
regulator - 3 wires to the stator (one going via the headlight switch) and a
red output and black earth wire.

I have several 6 wire versions in my shed and I was wondering if I could
replace it with one of them. Trouble is I can't work out where the sixth
wire connects to. On some regulators it's green and on others it's a brown
wire. I'm told the original Suzuki regulators will burn out frequently.

 

it is a voltage sensing wire , connect it direct to the + at the
battery

its easy to tell as you will have 3 yellow for the stator

2 thin wires which are your battery + and earth and the last will be a
thin wire

wire it all the way through direct to the battery and be sure to put a
fuse inline of the + often a 30 amp

bad connections cause an increase in current and heat , causing
failures

 

Thanks,
I had a look at my firends 80's GSX. It also has a 6 wire aftermarket
regulator.
The sixth wire is connected to the current side of the rear brake light
switch. Since this comes from the battery via the ignition ON switch will it
do to make a connection to the battery or should it be direct.?
On;y reason I ask is that I'm not keen on making extra connections at the
battery posts becausse they can corode and also make the battery complicated
to remove.

 

That 6th wire is a good idea. It acts as a power sensor, I think. Ended
up putting one on my old Suzy and, along with the addition of some good
earth wires from various components, my deaded stator and R/R problems
disappeared.

The 6th (brown?) wire is best spliced into the wire that feeds your
brake lights (just before the rear brake lever switch is good), as that
way it will only draw current when the key is turned on.

---
Cheers

PeterC [aka MildThing]
'81 Suzuki GS450-s (gone on to better and brighter things - I hope)
'87 BMW K100RT (write-off)
'81 Yamaha Virago (XV) 750H (work in progress)
'01 Yamaha FJR1300

www.dmcsc.org.au
http://eladesom.com.au/ulysses/
# 37181

 

By connecting it to something that is only live when the key is on, it
won't drain the battery while the bike is idle in the shed.

---
Cheers

PeterC [aka MildThing]
'81 Suzuki GS450-s (gone on to better and brighter things - I hope)
'87 BMW K100RT (write-off)
'81 Yamaha Virago (XV) 750H (work in progress)
'01 Yamaha FJR1300

www.dmcsc.org.au
http://eladesom.com.au/ulysses/
# 37181

 

Thanks PeterC,
You have been most helpful. I will wire it to the rear brake light switch as
per my mate's bike.
I don't know how long this Regulator will last. It's not the replacement
that bothers me as I have plenty of old ones lying around. It's the fact
that it always lets me down at the worst time, 100 miles from home and it
usually takes the stator and battery along with it.
Also would it be a good idea to wire the three stator wires direct to the
regulator rather than routing one through the headlight switch. I've heard
that using only two stator coils when the headlight is off is not a good
idea and it would be better to have them all active at all times?

Also advise on the web is to fit an Electrex unit which handles the heat
build-up better. Has anyone had any experience with them?

..

 

Been there. Done that. Got tired of it awful fast.

I've stuck with one going through the headlight, on the premises that
you only need the extra power when the headlight is switched on anyway,
and that otherwise the extra heat would build up in the unit which, I
suspect, contributes to the R/R failures. Not sure how sound my logic
was, but it seemed to work for me.



---
Cheers

PeterC [aka MildThing]
'81 Suzuki GS450-s (gone on to better and brighter things - I hope)
'87 BMW K100RT (write-off)
'81 Yamaha Virago (XV) 750H (work in progress)
'01 Yamaha FJR1300

www.dmcsc.org.au
http://eladesom.com.au/ulysses/
# 37181

 

"'81 Suzuki GS450-s (gone onto better and BRIGHTER things- I hope)"
a pun right ?
LOL

 

The old Suzy stator/battery/R/R setup has a great habit of failing. A common
symptom is the battery boiling dry because the stator is producing too much
current for it to handle, and the R/R unit can't do it either. You will find a
heap of info here http://www.thegsresources.com
Check out The Stator Pages. And the forum has many people who have solved
similar problems. The most common bit of advice is to clean, or solder, every
electrical connector on the bike, especially earth connectors.

Don't (that was a DON'T) wire up all your stator wires without reference to the
headlight, it will cook the battery. And once the battery is not drawing off the
current the stator will burn out. The headlight is a part of the current
management as the R/R unit can't take full load and needs the headlight as a
heat sink. It's better to wire it up through relays as the switch is very flimsy
brass - my switch has burnt out and I keep telling myself to get some relays,
still on the "to do" list.

Kim

 

I've got an Yamaha regulator on my GSX. (Don't ask me what model - it
has the right amount of wires)
It's been there from well before I bought the bike & I've done over
60,000 ks with no problems.

Bummers