Brown Plug in good nick shall I chop it out?????

Looked at my rectifier wiring last night and took the plug apart it is all in excellent condition with no signs of overheating..............




Now my dilemma is do I chop this plug out and solder the yellow wires together or leave it for now and just do the solenoid, extra earth strap to subframe and extra wires to the battery terminal???

Meter Reading and then I gotta go and mod sommat Else!!!!!!!

Right started bike up earlier and got the multimeter across the batt terminals with bike warmed up on idle and I am getting 13.9v thats with just the rear lights and front parking sidelight on.................


Flicked my modded swith which turns on the dipped beam and voltage stays constant at 13.9v on idle however flick the main beam on with all 3 headlights running and I get 12.7v constantly getting lower bit by bit on idle......just wondering whether by doing this mod the electrical system can actually cope with it!!!!!
Anyways the only mod I have done to leccy's so far is the extra earth wire from batt neg termonal to the subframe I used extra heavy duty speaker wire I had laying about here's some pics






So while all this is going on what does good ole me decide.................lets do some extra led's for the rear lights and so here are some pics of what I conjured up DOH this is getting addictive I should stick to the job I intended doing first




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Thats all mines got in 12v and cannot make out the rest of the writing asthe plating has corroded a bit .....I'm sure someone wil tell us shortly..............got any pics of your work I still wanna do some more research before doing my wires...........

Thats gr8 dude just what Iv'e been looking for can't go wrong with this one.......as I thought the other comments said join the to red/black & red/blue the other side of the white plug.......but this makes more sense........will go ahead with converting mine with pics this week

No going back now

Right decided too take the plunge and chop the brown plug out. I have decided too follow the digram fogg posted up at it makes more sense tapping into the loom on the rectifier side of the white plug for least resistance..............

So chopped the yellow wires each side of the brown plug and encounter my first problem..........yellow wires with ends trimmed are not long enough bahhhhhhhhh!!!!!!


So had to cut 3 lengths of wire to make them meet pushed the ends together so they are interlocking then solder them up don't forget to put your heatshrink on first


Next cut back the sheathing on one of the positive and one negative wire


Then I cut my wires with enough slack to reach the far side postive terminal of the battery and wrapped them around the exposed wire



Then soldered extra wires on


Heatshrinked and wrapped up with coloured polarity insulataion tape


Then crimped , soldered & heatshrinked some battery terminal connectors on the ends...........



And next .........I ran out of bloody solder!!!!!!! Humpfffff will now have to wait till I can get into town on thursday for more to finish the job, however I did just twist the rest of ac output yellow wiring together and connect the the battery again to see what readings I was now getting and....................................................

A slight improvement from before with 0.2v improvement with just sidelights running at idle now comes in at 14.1-14.2v
headlights same reading really at 13.8-13.9v


my big surprise though was with all 3 headlights running I am still only producing 12.0v max at idle.............maybe I will still improve on these figures yet once I connect the extra wires on the output side of the regulator up and the rest of the ac wires are soldered together..............watch this space

oh while I had the camera out here is my other bikeits an original GSXR750M 91' last of the oil cooled motors hopefully now appreciating in value...............

SteveR said:

Ha I ran out of solder too! what a git. I`v given up trying to fit the extra wires in the block connector from the reg rec. As I`v butchered my plug trying... so I`m just going to get single connectors to replace the block.
Im surprised you havent gained more, what is it at 4k? as the issue usually means it drops when you rev it, but after the mod it stays more constant..

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Yes I expect I will gain a little more voltage as I only had 1 of the ac charging wires actually soldered together when I tested it and twisted the other 2 yellows together also the positive and negative extra cables were not attatched to the battery which I expect will bump it up considerably ...........but I'll wait till I get some more solder get all the connections sucurely tightened down then do another test read..............

I was expecting mine too be long enough not to have put in the extra pieces of wire...............wouldn't have run out of solder otherwise............ho hum