Aftermarket R/R is too wide, any suggestions on moving components?

[Dmason]

I recently purchased an aftermarket R/R from RM Stator. The details said that it was a direct replacement, plug and play, blah blah blah. When my mechanic went to put it on, he found that it was too wide. The Tri Igniter is in the way, and the new RR wont fit. The original RR is much slimmer, not nearly as wide. Additionally, theres a ground wire coming out of the new RR, and I guess there's a wire he doesn't know where to put. Mind you that this mechanic works on cars, and rarely on motorcylces.

Does anyone have a suggestion on how to fit the new RR on, or even where I could find a wiring diagram? Any help would be appreciated. I know this is a newb question, but this is the only thing holding my back back from being on the road.

Thanks for your time.


Additional info: My bike is a 1981 GS 450E

[BassCliff]

Greetings and Salutations!!

Hi Mr. DMason,

Normally the r/r unit goes on the side or the bottom of the battery box. But it doesn't have to go there. Mount it anywhere there is room. Some folks have even mounted it to the front of their frame to keep it out in the moving air for cooling.

How many wires does this r/r (regulator/rectifier) have? What kind of documentation did you receive with it? I've used RM Stator stators but never a r/r unit from them.

You'll find a manual and wiring diagram on my website. Before I go any further, let me properly welcome you.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", the Carb Rebuild Series, and the Stator Papers. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[Dmason]

Hi Mr. DMason,

Normally the r/r unit goes on the side or the bottom of the battery box. But it doesn't have to go there. Mount it anywhere there is room. Some folks have even mounted it to the front of their frame to keep it out in the moving air for cooling.

How many wires does this r/r (regulator/rectifier) have? What kind of documentation did you receive with it? I've used RM Stator stators but never a r/r unit from them.

You'll find a manual and wiring diagram on my website. Before I go any further, let me properly welcome you.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", the Carb Rebuild Series, and the Stator Papers. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

Thanks for the welcome. I actually signed up here 2 years ago, but with the forum changes, I had to re-sign up.

Putting the R/R anywhere is good to know. When it came from RM Stator, it only came with a few tips on safety, nothing in terms of technical instructions.



Thats what the RR looks like. I can have an actual pic of it up tomorrow when I see my guy. I'll take a pic of the OEM RR and the new one together.

Thanks for your help. There is nothing more relieving than getting help from someone who knows their stuff, especially when you're in a bind and the nearest Suzuki dealership is an hour away.

[Nessism]

Just find some place to mount it and hook it up. The yellow wires go directly to the stator outputs, color doesn't matter on these, that red is hot, and the loop goes to the negative battery terminal or to a good frame ground (not the battery box which typically grounds though rubber gromments). Dead easy to hook up.

[BassCliff]

Hi,

Yes, what Mr. Nessism said. He really knows his stuff.

You have a standard "5 wire" r/r unit. The diagram below is for a 6 wire unit. You can disregard the sixth wire, called the "sense" wire (blue), that connects to the tail light.




Thank you for your indulgence,

BassCliff

[Paul_IOFJS]

Why green?

I just have one question about the Honda (6 wire) r/r. WHY do the use a green wire for ground and a black wire for a signal (sense) wire?!? DC electrical basics are that the ground is always black! Why do they go and mess with us like that, they are just begging to have someone connect it wrong and screw things up! Sorry for the rant, but it just frustrates the heck out of me when people do that.

[BassCliff]

Hi,

I think that's one of the reasons it's called a "Hon-duh".


Thank you for your indulgence,

BassCliff

[Dmason]

Thanks to Cliff and Nessim for the help. My bike is fully charging again. But as one problem is fixed, another pops up. Looks like its time to post in the carb section...