Electrex R/R Mounting Help.....PLEASE?

[joejeweler]

Hi all,.......i ordered one of the Electrex regulators/rectifiers a few weeks ago to replace the functioning (for now!) stock unit, ('82 GS850GL)...... and was going to put it in last weekend when i had the carbs and airbox out figuring i had more room to work.....

..............repair manual makes it sound pretty simple,.......just remove the two screws on the bottom of the battery box,,,,,,,,,,,,YEAH RIGHT!

...............with WHAT? I've got 8 different size (lengths) phillips screwdrivers and none of them can gain access to the damn screws. Seems a little thing like the swing arm with very little clearence are in the way! I suspect even if i could get at them they'd be locked on same as the ones on the side of the battery box holding the relays. (see below)

So i decide to go at it from a different angle and remove the battery and remove the two battery box retaining bolts with the intent to pivit the box around & have the screws face upright. But the electric relays and such on either side have phillips screws also seemingly WELDED on to the battery box,..........and those i had access to! Gave that idea up and reconnected all the wires.

Damn Suzuki for not using allens or even hex bolts that a socket could get at.

Anyway, i was thinking of picking up a pair of locking grip pliers and maybe break them loose,.......if i can get at thel this way. I plan on replacing the bolts with hex or allens anyway,........so not concerned about how they look.

One other thought crossed my mind when i had the battery out. The bolts that hold the R/R on come thru the battery box. I was thinking of drilling out the screws to just shy of the threads. (hopefully!)

Anybody tried this to satisfaction? Any suggestions to get the screws out "normally". (even if that means bringing the bike in to a Suzuki dealer nearby!).

OH,......one other pet peave. The write-up on the Electrex R/R stated that it was designed and made in the US. Mine came thru with the box stating designed in the USA,.......made in CHINA! What the ...k?

......better edit the write-up 'cause i's sure i'm not the only unhappy camper.

[rustybronco]

An impact screwdriver that is about $10-15.00 at the local auto parts, if you buy nothing else in the way of tools in your life... GET IT!, penetrating oil, and a propane torch used WISELY!!!!!!! to loosen the screws, NOT near the wires, electrical components, battery plus a can of spray paint for when your done.

[rustybronco]

Damn Suzuki for not using allens or even hex bolts that a socket could get at.

Damn rust!, not Suzuki, it doesn't come factory installed.

[Road_Clam]

When I restored all the components in and around the battery, I quickly realized a major issue ACIDIC VAPOR CORROSION. I blasted, primed, and painted all the components, and made sure I anti-siezed all the bolts. Make sure your battery vent hose is there, AND the hose outlet is mounted as low as possible near the ground. This keeps the corrosive vapor away from the electrical components.

BTW, during my rest, my #1 friend and neccesity was an IMPACT DRIVER.
Rich

[joejeweler]

Impact driver,.....had one years ago,.....plan to get another for easy access areas,......but NO Way you can even use one that i see on this job. Remember,......the screws are up under the battery box with the swing arm blocking access.

...........so what i could use is info on how some of you guys actually got the job done,........without wanting to throw something!

BTW,.....my bike looks to be rust free save for a VERY slight surface spot or two under the seat and such. Battery vent hose still doing it's job,......no visable rust anywhere around the battery box. Bike now has 12,000 miles on it and appears stored properly for many years in a temp controlled spot.

[rustybronco]

remove battery box thats what i did, then heated the nuts and sprayed them with penetrating oil. 1982 gs850g