R/R install... CORRECTLY

[Guest]

Picked up a 1984 GS450L $300, r/r was cooked, runs good, 5 wire hook up, should I plug into the factory plug for all wires or cut off the flat plug and make my connections separatly, 3 to stator, green to ground, red to positive side of battery or into harness? also should I install a inline fuse between the batt.+ and the R/R + I will make sure battery is charged and topped off with distilled water. Also will clean connections. Don't have a manual yet for the Gs 450, but am I to understand that there is (1) main fuse verses my 80 750 with (5) glass type fuses. Both bikes will get up grades as funds allow. Stator tested around 60 on all 3 legs.

[tom203]

Wire the stator direct to R/R, wire R/R positive output to harness (as it came from factory)' add good grounding between R/R, frame, and battery. Buy a SH-775 or Compufire and live happy!

[Steve]

Do you have your replacement R/R yet? Step-by-step, "idiot-proof" instructions will depend a bit on what R/R you install.

We heartily recommend the Polaris series-type R/R, which will cost you about $70. However, since you are mentioning wire colors, it appears that you have already committed to a lesser R/R. Good luck.

Regardless of what you install, there are some basics that remain:
1. There are three wires coming from the stator, there are three inputs on the R/R. They should be connected DIRECTLY, with NO detours through other wires that might be in the harness.
2. Connect the red output wire of the R/R to the original red wire in the bike's harness. If you do this, you will need not additional fuse.
3. Check the ground location for your R/R. Some are connected to the battery box, which is rubber-mounted and relies on yet another wire for a ground. Probably best to connect the R/R ground wire directly to the frame or the battery.

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[Nessism]

Wire the stator direct to R/R, wire R/R positive output to harness (as it came from factory)' add good grounding between R/R, frame, and battery. Buy a SH-775 or Compufire and live happy!

This covers it. Bypass the factory harness. Keep stator wire run to R/R as short as possible. Only other thing to do is make sure you don't have excess resistance between R/R positive output side on the way to the battery. Take your voltmeter and put one probe on the R/R positive output connection to the harness and the other on the + battery terminal, and then rev up the engine to 5000 rpm. If you see more than 1/2 volt you need to take apart the connections along the route back to the battery and clean them.

[jbird7262]

Yep, Don't all yell at once.... Electrosport 5 wire for the 450, will get the higher end R/R for the 750E, we learn by our mistakes.