Help needed with new RR install & the headlight switch circuit...

[Guest]

I am attempting to install the Electrosport RR for my '79 GS425. It is my understanding that something should be done to correct/alter the white/red white/green circuit that goes from one phase wire of the stator to the harness to the headlight switch to the RR.

How, exactly, should this circuit be altered in order to improve it?

Thank you!

[tom203]

".......It is my understanding that something should be done to correct/alter "
you need to do some reading on this problem, cuz you already have made an error by the e/s r/r route. Start with this link- there's more to know

http://www.thegsresources.com/_forum/showthread.php?152769-GS-Charging-System-Health&p=1138531#post1138531

[MidWestCoast442]

Wow. Wtf? Can someone please update the MF'ing stator papers so that we have good and relevant information on there?

So wtf should I do? Return the electrosport RR and order a series RR?

Suggestions???

[tom203]

Wow. Wtf? Can someone please update the MF'ing stator papers so that we have good and relevant information on there?

So wtf should I do? Return the electrosport RR and order a series RR?

Suggestions???

Return the E/S and get a SH -775 unit- your bike will be grateful and be more reliable
while I'm here, do you have a 442' 1970 vintage?

[JTGS850GL]

The Electrosport R/R will work just fine if you don't want to, or can't return it. Not sure if the Electrosport R/R is a series or shunt design though.

[mikerophone]

The Electrosport R/R will work just fine if you don't want to, or can't return it. Not sure if the Electrosport R/R is a series or shunt design though.

It it shunt.

[uk gs nut]

Go here and have a read, http://www.thegsresources.com/_forum...le-again/page2

[mikerophone]

Go here and have a read, http://www.thegsresources.com/_forum...le-again/page2

+1 to getting a Honda unit from Duaneage if you stay with the shunt type. They are very well built and from what I hear he does a great job. Depending on the "crispness" of your stator and condition of the wiring and connectors, a shunt type R/R may last you a long time yet.

Some say get a series, and that even with a somewhat crispy stator, as long as it's still putting out adequate and equal voltages across all 3 legs it can be saved.

Do you know the condition of your stator?

I need to do the headlight circuit bypass on my new 850 as well. Have you searched it out yet, I haven't gotten that far, still tearing it down...

[MidWestCoast442]

Goddam. What a PITA.

Tom: I have a 1965 442.

Mike: I don't know the condition of the stator. Figured it would be good to replace the RR, regardless. I'll look into the RR's from Duaneage and the series RR's. I haven't been able to find a diagram for the headlight circuit bypass.

[JTGS850GL]

I haven't been able to find a diagram for the headlight circuit bypass.

The "headlamp circuit bypass" is simple. On the stock wiring you have three wires coming from the stator. Two wires go straight to the R/R and one wire goes into the main harness. It loops through the headlight bucket and then back to the R/R. Originally there was a headlamp switch that allowed you to turn off the headlamp. The reason for the headlamp loop was to cut one leg of the stator output off when the headlamp was off. This allowed for less current shunted through the R/R and was supposed to keep the stator and R/R from burning out. Once the Feds made it mandatory for the headlights to be on at all time on motorcycles the switch was removed. Rather then modify the harness for the USA they simply connected the two wires together and removed the headlamp switch altogether. The headlight bypass simply connects that third leg of the stator directly to the R/R without going through the main harness and headlamp assembly. This removes several connectors and several feet of wire that's not needed from the charge circuit. What made this all a little more confusing is that the stator wire connected to the main harness through one color wire (Green/White) and was brought back to the R/R through a wire of a different color (Red/White).

Here's a link to the 425 wiring diagram that will help: 425 Wiring Diagram

In the diagram you'll see a Green/White wire leaving the stator and a Red/White wire returning from the headlamp switch and going to the R/R. You simply connect the Green/White wire to the R/R Red/White wire and leave the wires going to the main harness open.

The truth is that any of the three stator wires can connect to any of the three R/R input wires. There is no difference between the three stator wires. Most aftermarket stators use the same color wire on all three. Usually yellow.

Hope this helps

[tom203]

Have some fun reading this thread (note final instructions)- this comes up all the time

http://www.thegsresources.com/_forum/showthread.php?225027-SH775-and-Headlight-bypass&p=2092883#post2092883

[mikerophone]

Hope this helps

Indeed it does, and yes very simple, thank you!

[posplayr]

Wow. Wtf? Can someone please update the MF'ing stator papers so that we have good and relevant information on there?

So wtf should I do? Return the electrosport RR and order a series RR?

Suggestions???

So I assume you saw this..............

http://www.thegsresources.com/_forum/showthread.php?191795-GS-Stator

[MidWestCoast442]

Okay. Thanks for all of the help. I'm going to order an RR from Duaneage and see how it goes.

In regards to the headlight switch circuit - My bike has an on/off switch. So cutting-out that loop and wiring the white/red wire directly to the stator will not affect my ability to turn the headlight on & off?

[SVSooke]

Did it on my 78 1000,light still turns on and off.