Help me build a reliable electrical setup!!

[Kara25]

Hello everyone. Due to a new job i got the bike will be my main means of transportation from now on. That means to me a sturdy and good working electrical/charging system setted up in advance now so i dont have any unpleasant suprises later. I am sure you gurus can pinpoint flaws even from some pics and give me some general tips. I have on order right now a new Ricks starter a new Ricks 18 pole stator and a new lithium battery type R/R plus a 2 month old new Lithium ion Skyrich battery. In the past 2 years i was using the same battery but with an R/R that the PO had on the bike which i think is not to be used with lithium batteries long story short due to winter inactivity and me forgeting to remove the battery from the bike it died so i had to buy a new one while i overhaul /replace all the components. Pics that follow: stator-rotor-grounds-R/R connections from PO-R/R mount point-igniter ground. Please feel free to tell me what horrors you notice �� 20220209_095600 by Geo 25, on Flickr 20220209_094941 by Geo 25, on Flickr 20220209_095112 by Geo 25, on Flickr 20220209_094916 by Geo 25, on Flickr 20220209_094729 by Geo 25, on Flickr 20220209_095308 by Geo 25, on Flickr 20220209_100711 by Geo 25, on Flickr

[Gorminrider]

Hi, Kara. There's a lot of after-market crimpon connections ! Some of them are soldered, which is probably better than not being, given the funkiness of most of them... the one with the green wires (from the regulator are really not great at all.You should not see bare wire coming out of an crimp. The vinyl insulation should be held by the back of the crimped connection under the sleeve.... I'd give all the unsoldered crimps hard pull and see if they come apart...ugh. and Avoid hard bends of the wire near a soldered connection... solder should not be required. or used for that matter.

and then there's the butt joins of wire under those shrink tubes....the electrical system has definitely had some rough handling.

That said, cheezy auto-parts store connectors like these CAN be "ok" with a proper crimping tool -they e at least fairly stiff-and some skill getting a portion of the wire insulation into the plastic sleeve as a "stress cushion" but really, the best way to go is to duplicate original quality bullet crimp-on connectors exactly, again, with a proper crimping tool for them.

ALL that said, you might get a lot of miles out if doing nothing, but they are not pretty and bikers that are serious are going to weep and whine when they see them.

[Kara25]

Yeah thats a hornet nest i know curious of how should i proceed with the new parts. Now the stator is hardwired directly to the wires going to the R/R no bullet connectors.Should i do the same with the new one or better to add bullets to the wires going to the stator? As for the R/R i see they kept the OEM plug in connector in place if you see on the picture of the fusebox is wraped in tape.Yesterday i uncovered a horror when i unwraped it.all wires going to the female end of the plug are GREEN of corrosion and one of them is completely broken off. Should i hardwire the new R/R to the wire that comes from the stator and in doing so eliminate the plug connector??

[Gorminrider]

I prefer to have the stator with the connectors. There's a lot of current going through them so they need be GOOD ones well-crimped. OR splice to the original wires with their existing connectors...

Of course, you can hard-wire it in,without connectors, but if you ever want to disconnect it, re-route the wires, test it, etc... it's much harder without the plug connection. And every time you hardwire something in, the wires get shorter as you trim for fresh,new ends.

Looks like the old r/r is a Honda type or a clone of one. Green is ground on old Hondas. Suzuki just has bullet connectors on the three stator wires....

added: I can appreciate it'll be hard to know what normal was on that bike but you can tell which were bullet connectors and which were multi-connectors from the SHOP manual's wiring diagram..wiring.jpg

[Kara25]

Thanks a lot man when all my new parts arrive i will see how much i can accomplish on my own and thankfully i have a trusty car electrician as a friend if it goes over my abilities i will tell him the tips that you shared so we make this thing reliable above else!

[Gorminrider]

Main thing is to ride it and then, to understand it. Don't get stuck in the shop unless that really is your passion. Smaller bikes tend to have a lot of previous owners, so what you understand to be solid and working doesn't need or merit a rebuild. Not until unrideable weather anyways.