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Thread: RSV Voltage Regulator Wiring Modification

  1. #1
    amb67
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    RSV Voltage Regulator Wiring Modification

    RSV Voltage Regulator Wiring Modification

    A word of warning is in order first, if you carry out this modification you do so at your own risk. If you are unsure of any aspect of this wiring modification then please ask before you start modifying your bikes wiring loom.

    Remember to read this whole document at least once from start to end before attempting the modification.

    You will need to be able to solder in order to complete this wiring modification.
    Before you start, DISCONNECT THE BATTERY.


    Questions & Answers

    1. What made me modify my RSV voltage regulator wiring loom?

    When I go out for a ride, I want to ride and not have to call my recovery company to take me home.

    I had read many threads on various forums about charging issues, the dreaded brown connector, poor starting and the list goes on. I decided that action needed to be taken and compiled a definitive ‘How to’ from all the threads I had read along with firsthand experience of carrying out the mod on my RSV.

    2. I ran my bike up for around 30 minutes whilst tinkering with another part of the bike, I shut down the engine and thought of how to kill some time. I decided to check the condition of the terminals in my large brown connector at the voltage regulator, at this point I tried to place a hand on the brown connector to pull it apart and it burnt me.

    I let it cool down and pulled apart the connector, the terminals looked quite clean with just a small amount of corrosion evident. (My connector was cable tied to the rear frame and its positioning was allowing water to run down the frame straight in to the connector, very poor design.)

    After the modification these wires get warm whilst the engine is running but nowhere near as hot as when the brown plug was in place. My brown connector was obviously causing some resistance in the circuit thus creating the heat that burnt my hand.

    I have broken this modification down in to two stages, this makes it easier to understand and follow. (Less chance of error too)


    Wiring Modification Part 1

    Cut the three thick yellow wires at the brown plug (As close to the plug as possible) and solder the connections as per the photos below.

    The yellow wires may not quite be long enough once the brown connector has been removed, they do have some give in the loom end, give them a very gentle tug and you’ll gain another 2 cm of length this will be enough to allow you to make a good soldered connection.

    The brown connector showing the yellow wires cut off flush.



    Three yellow wires connected individually and insulated.



    The three yellow wires bound by insulation tape.



    **NOTE** When cutting the three large yellow wires I did mine one at a time just in case they all got muddled up and for some unknown reason caused me charging problems.

    Once all the yellow wires have been soldered make sure that they are well insulated from each other and the other wires in that area.

    Don’t forget to cable tie the loom back to the frame once you’ve finished. (Mine wasn’t at this stage)



    Wiring Modification Part 2

    This part involves modifying the voltage regulator output wiring. Don’t worry this is the easy part.

    Just remember that all you are doing is adding in some extra wire to assist the existing wiring loom.

    No fancy silicone wire is needed here, get some three core cable about 18” long, part of an old extension lead will do for this job. Strip off the outer casing so you have three separate wires and place to one side for now.

    The first cable I added goes from the red with black tracer wire at the white plug to the red with black tracer wire at the 30A fuse block at the side of the battery. (Just near the starter solenoid)

    (If you look closely you can just see the green wire I added disappear under the frame on its way to the 30A fuse holder)



    I like my wiring to look untouched and tidy so I threaded my additional wire up the black plastic sheath covering the loom that carries the red/black from the voltage regulator to the 30A fuse. Be warned this was a complete pain in the arse to do but I felt that it needed to be done on my bike.

    This is the black sheath that I threaded my cable through.



    I also connected an extra earth cable for the voltage regulator, this goes from the red with blue tracer wire at the voltage regulator white plug to the negative terminal of the battery.

    This additional earth wire can be soldered on to an existing connector at the battery negative terminal or in my case I added a ring terminal to the end of the cable and secured it to the battery terminal that way.

    Again, just use one of those strands of wire stripped out of your three core cable you acquired earlier.

    The finished product, you’d never know that I had been in there, would you?



    Summary

    Before I carried out this modification I had 13.80 Volts at the battery, tested using my Fluke. (Note, the dash voltage read at 12.2 Volts)

    After the modifications I had 14.2 Volts at the battery, tested using my Fluke. (Note, the dash voltage read 13.2 volts)

    All voltage readings were taken with the engine idling and no ancillaries activated.

    As you can see not much of a gain in voltage at the battery but I now feel assured that my charging circuit is in tip top condition.

    Please feel free to ask if you have any questions.

    Wiring diagram:


  2. #2
    AMA Pit Boss Sprocker's Avatar
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    Excellent write-up...again

    Is this for all models amb , mines a 2000. I'm working on my bike today (finishing the clutch) so i'll whip the panels off and check if mine has the brown connector and do this mod while i'm at it.

    Top stuff your doing mate

    Forgot to add...STOP BITING YOUR FINGERNAILS
    Last edited by sprocker; November 20th, 2008 at 01:55 AM.

  3. #3
    amb67
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    Quote Originally Posted by sprocker View Post
    Excellent write-up...again

    Is this for all models amb , mines a 2000. I'm working on my bike today (finishing the clutch) so i'll whip the panels off and check if mine has the brown connector and do this mod while i'm at it.

    Top stuff your doing mate

    Forgot to add...STOP BITING YOUR FINGERNAILS
    Hi Sprocker,

    On some of the posts I read whilst researching this mod the bikes involved where 2000 model RSV's. (Mines a 2001)

    Can't stop biting my nails, 4 kids mate and you'd be down to the knuckles too. LOL

  4. #4
    Super Garvey Garvey2003's Avatar
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    Fingers crossed I haven't had a charge problem yet. Use the bike everyday.
    Might have look for the brown wire this weekend, if I have it then I guess I might have a go. I have some heat shrink for cables I haven't had chance to use yet aslwell lol.

    Might need a lift to work on monday lol

  5. #5
    gaz
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    good write up bud and well done for bringing up the post.

    Are some of those pics of a futara by any chance? or does the later rsv have the reg down by the motor?

  6. #6
    amb67
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    Quote Originally Posted by gaz View Post
    good write up bud and well done for bringing up the post.

    Are some of those pics of a futara by any chance? or does the later rsv have the reg down by the motor?
    Yeah, the one under the brown connector image was borrowed from the tinternet, damn camera took a blurred shot.

    Bit of luck it'll save some RSV's being recovered home next summer.

    Have fun doing the mod and don't be afraid to ask questions. It's cheaper than buying bits for your bike.


  7. #7
    BB1000
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    I got the same voltage results when i took the pins out the white connector and added solder to the crimped wire, i bypassed the brown connectors to

  8. #8
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    My "white" connector was so corroded both halves were practically welded together !!, now replaced with a "spare" connector from my old R1.

    One thing I think that should be checked and checked again is the condition of the white connectors terminals , this is vital in my opinion.

    If in doubt cut out the white plug too.

  9. #9
    AMA Pit Boss rs3 mille's Avatar
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    solder whats that then and a fluke (thats normally asociated with chelsea fluke that is)

  10. #10
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    solder = someone in a uniform wiv a gun
    fluke = a worm that lives in yer guts if ya drink too much an eat burgers

    :-)

  11. #11
    AMA Pit Boss rs3 mille's Avatar
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    Quote Originally Posted by kiwi_rsvr View Post
    solder = someone in a uniform wiv a gun
    fluke = a worm that lives in yer guts if ya drink too much an eat burgers

    :-)
    cool
    thanks buddy cleared that one right up

  12. #12
    AMA Pit Boss Sprocker's Avatar
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    Can of worms !!!

    Well i started off with the intention of doing the brown connector mod



    But when I disconnected the battery the alarm was doing its alarmy thing and driving me fookin nuts going off every 30 seconds

    So...I took the ecu off and found this lot



    So....a little tidy up required


    And this is what ended up on the floor


    Sick of the alarm going off everytime i took the seat off,arming itself while filling up at petrol stations etc....pain in the arse things anyway

    Oh ..still got brown connector to do tomorrow too

  13. #13
    Super Garvey Garvey2003's Avatar
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    lol what alarm is it and you want rid? after an alarm as its a dodgy area at my work

    good job on the wires matie

  14. #14
    A303
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    Nice post AMB, I'll be trying that one. Thanks.

  15. #15
    AMA Pit Boss Sprocker's Avatar
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    Quote Originally Posted by garvey2003 View Post
    lol what alarm is it and you want rid? after an alarm as its a dodgy area at my work

    good job on the wires matie
    It's a Datatool System 3 but theres no wiring diagrams. it was already fitted when i bought the bike.

  16. #16
    AMA Pit Boss AREESSMILL's Avatar
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    Great write up Alan

    When Ive got a spare 3 weeks ill give it a go.

  17. #17
    AMA Pit Boss AREESSMILL's Avatar
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    Right ive done the brown connector mod.

    But i am a bit lost on the rectifier bypass, can anyone give me a hand please?

    Thanks

    Tim

  18. #18
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    how do you mean lost ?

    on the white plug there are 2 sets of wires 2 should be red with black traces and 2 slightly thinner red wires with blue traces.
    Pick one of the red/black wires and add another wire to it , this wire then goes to the 30amp fuse block where it joins a red/black wire.
    you then do a similar thing for one of the red/blue wires but this goes to the battery negative terminal.
    Try and make the joins as close to the plug as possible.

  19. #19
    AMA Pit Boss AREESSMILL's Avatar
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    Quote Originally Posted by kiwi_rsvr View Post
    how do you mean lost ?

    on the white plug there are 2 sets of wires 2 should be red with black traces and 2 slightly thinner red wires with blue traces.
    Pick one of the red/black wires and add another wire to it , this wire then goes to the 30amp fuse block where it joins a red/black wire.
    you then do a similar thing for one of the red/blue wires but this goes to the battery negative terminal.
    Try and make the joins as close to the plug as possible.
    Cheers

    I was a bit lost as to whether or not i had to join the 2 red black wires together, then run a wire from them to the fuse.

    Same thing for the Red blue wires.

    Would it not be better to bypass the White connector altogether and add our 2 wires directly to the green and red wires??


    ps Does it not matter what red/black wire we choose??

  20. #20
    AMA Pit Boss Sprocker's Avatar
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    Just bypassed both plugs today, but didn't bother with the extra wire to the fuse holder tho'. I got 14.2 volts at the battery with 13.8 on the dash with engine running

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