Help with the 6th wire on R/R

[Johnny K]

Many questions about this but I ordered the duneage special (thank you by the way). It's amazing how massive it is compared to my stock one (I made a funny). That 6th wire has a split at the end with 2 more connectors. Very confused about that. My original had 5 wires. I think that 6th wire I dont need, but not sure what to do with it. Just confused on BassCliffs pictorals and what he did with that 6th wire. So the 3 yellow wires from the R/R connect with my three multicolor wires in any order and it doesn't matter? The red wire I can figure out goes with the other red wire coming out of the R/R. Would it kind of be a mess if I didn't like the connectors that came with the R/R and would want to put different ones on? The wires that are in my pic are short. If I were to just connect the wires with the R/R, it would be in front of the fuse box, and not be able to re-wire it underneath it or over it. Was wondering if I could put a jumper on each wire to wire would be too much clutter? But it would make the wires longer to re-route to go over the fuse box like other two connectors are. Thanks again.

http://i86.photobucket.com/albums/k95/jjkay24/RR/P1010195.jpg

http://i86.photobucket.com/albums/k95/jjkay24/RR/P1010190.jpg

[BassCliff]

Cooking with electrons

That 6th wire has a split at the end with 2 more connectors. Very confused about that.

Hi Mr. Johnny K,

Nothing to be confused about. That is the "sense" wire. It monitors (or senses) the voltage in the harness so that the regulator can vary its output properly. I plugged mine into the brake light switch. On the right side of your bike, probably under the sidecover near the rear brake master cylinder, you'll see where the brake pedal has a spring wire running up to the brake light switch. When you press on the rear brake pedal it pulls the switch and turns on the brake light. Disconnect the wire powering the switch (I think it's brown) and plug in the wire with the 2 connectors in between the open connections (don't disconnect the wire that pulls the switch). That wire has a "Y" in it so that you can connect the sense wire and still leave the circuit connected to the brake light. (In other words, plug those 2 connectors in between the wire you've disconnected on the brake switch.)

The sixth wire should be connected for this r/r, don't leave it disconnected.

I've replaced all of the bullet connectors in the charging system with blade connectors. I think it's a good thing. I did leave the bullet connectors on the brake switch connections because the wire was kind of short and I didn't want to splice in more wire. Splicing in more wire for length is OK if you use solder connections and shrink tubing rather than crimp connectors. Crimp connectors have a higher failure rate, but can last a long time if done properly.

The three output wires from the stator can connect to the three input wires of the r/r in any order (consider them all yellow). Then connect your hot wire (red), ground wire (directly to the negative terminal of the battery), sense wire (to brake switch), and you're done.

Now may be a good time to check and clean every bullet connector and ground connection on your entire bike. These bikes love clean electrical connections. Keep us informed.

Thank you for your indulgence,

BassCliff

[Steve]

I recently installed a Duaneage r/r, so I have recent experience with the sixth wire. If you look carefully, you will find that it is just long enough to reach to the connectors that lead to the tail light, just behind the battery. If you unplug the tail light connector, you can then install the connectors on the sixth wire. All it does is tap into the tail light wire to monitor system voltage.

.

[duaneage]

This might help, I thought I sent one already

[Johnny K]

Yup Mr Duneage you did and it was just a little confusing, but thanks for the explanation. Im just not so good with wiring diagrams but I understand it now. Thanks alot guys for the replies. I also ordered a new stator and will be coming hopefully monday and will take out the old one and put in the new one. I have actually replaced, cleaned and greased all the connectors. It's coming along pretty good. The stator readings were ok, but when I looked at it, there were a couple of coils that were half wire and half coating with that insulation stuff. My battery is good. So I just figured replace the R/R and stator and not have to question about the stator. When it's all up and running I will keep you guys informed. Thanks again for the replies.

[rustybronco]

Under the lh side cover there is a white connector where 8? wires plug together. on the top of that connector is a orange/white wire that is hot with the key on.
mine is connected there... gs850gz

[Johnny K]

Okay, I went to the brake light switch and realized that it had 2 wires meaning 4 connectors. Here are my pics and just wondering where the new R/R double 6th wire connects with and then where do the other 2 wires go? Thanks guys.

Two wires connected

http://i86.photobucket.com/albums/k95/jjkay24/Battery%20switch/P1010197.jpg

The left side wires lead to the brake switch and the right wires lead to the wiring harness.

http://i86.photobucket.com/albums/k95/jjkay24/Battery%20switch/P1010199.jpg

[duaneage]

Unhook the orange wires.
Run the female orange into the male black wire connector and the male orange connector into the matching female connector on the other black wire.

leave the white wire connected.

Test the rear brake light before driving the bike to make sure it works properly.

Should be good to go.

[Johnny K]

Awesome. Thanks. I will let you ya know how it comes out.