My 60th birthday present

As well you should. What you make will be every bit as good as what they sell and a good $100 cheaper. Frankly, I just shake my head whenever I see those linked to. If the 1100 guys are buying that stuff they must have very little understanding of their electrical systems. Look at the regulator unit used. I'm almost certain it's this regulator you can buy for less than $12 .....

http://www.ebay.com/itm/122128766123?_trksid=p2060778.m1438.l2649&ssPageName=STRK:MEBIDX:IT

I doubt the rectifier used cost any more. But, if you want to pay somebody $125 for a piece of plate, a few wires, and two plugs, be my guest, lol.

RG,
Well that's interesting! I'm going to have to go back and re read that section of the manual again. Thanks!

5twins said:

I doubt the rectifier used cost any more. But, if you want to pay somebody $125 for a piece of plate, a few wires, and two plugs, be my guest, lol.

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Yeah, I thought that was pretty expensive as well.

Its great to see that Mailman wants to make up his own rectifier and regulator. One of the main reasons to own and run these bikes, is that they are simple, easy to work on, and inexpensive nos automotive parts are readily available.

Yeah, I also suspect the 1100 lads don't really understand the electrics on their bikes. I find that many people on the internet forums are just "follow the leader" types. They just follow what someone else did, in a previous posting, and don't do any research on their own to find a better cheaper way..

First, I don't fault anyone for enjoying the convenience of buying a ready-made product. I also don't fault anyone for making a profit by producing a ready-made product.

But I, like Bob, 5twins, and most on this forum, get a great pleasure out of learning about and understanding their machines. One of my favorite Pirsig quotes is "He (John) thinks I'm working on parts. I'm working on concepts.” By creating a DIY reg/rec, you are learning about the bike. For me, this is way more valuable then the convenience of, say, letting a shop fix it.

when my vr on my xs1b was acting up, I adjusted it, was working just fine, but the reaction time was a little slow for me, so I installed the vr-115. its smooth and steady. I kept the working original as a back up.
Mail man, that clutch cover turned out really nice. You should clear it over so it stays that way

And we're really not totally building these things, just wiring them up. Once you have a basic understanding of how the charging system works, and which type of regulator (ground or power switching) is required, then it's easy to find cheap automotive units.

angus67 said:

when my vr on my xs1b was acting up, I adjusted it, was working just fine, but the reaction time was a little slow for me, so I installed the vr-115. its smooth and steady. I kept the working original as a back up.
Mail man, that clutch cover turned out really nice. You should clear it over so it stays that way

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Yes Angus, the original mechanical regulators are well built and have lasted a long, long time, because of their original high quality manufacturing. However they are mechanical, and things such as springs/levers and contacts wear over time with the result the calibration is no longer what it was when it came from the factory, and voltages can vary. When I removed my OEM regulator it was still working, and I could still put it on the bike today and it would work. They are very rugged.
I just prefer the VR-115 because it was designed for 60 amp alternators, which means for our 16 amp alternators it is heavy duty, and is not working hard at all. Voltages are always the same and rock steady.

The "rock steady" part is the important thing and benefit. Yes, the original may still work, and continue to do so for a long time, but it's output is all over the place, constantly fluctuating up and down.

Sounds like you are closing in on it MM.

BTW - that RH side engine case looks spectacular. I gotta get me some of that Blue Magic!

Part one, charging system update.

Rain, rain, rain, three days straight now. VERY un Phoenix like.

Last week I ordered a new VR-115 voltage regulator to replace my aging mechanical unit and also at the same time a new rectifier from China. So while my rectifier is on a slow boat, my regulator arrived a few days ago.
I don't need to reinvent the wheel here, many on this forum have already done this, but hell, I like to take pictures, so here we go.
First off I'm just going to say, 5 Twins has already done some excellent write ups on this, so I decided to just copy some of his work. Haha! Thanks 5 T!


He came up with a cool idea for a mounting plate which mounts it right in the factory location. He fabricated a new wiring harness extension, but I chose to cut the regulator plug off and solder the old wiring harness to the wires coming from the regulator. I sealed everything up with heat shrink tubing, and the wiring was plenty long enough to reach. All in all the look is very sanitary, almost factory. That is if the factory were staffed by old beer drinking shade tree mechanics!


I chose to leave it the plated silver look just the way it came, I kind of like it. I also used the factory rubber mount system that was on my original regulator.


When my rectifier gets here I'll post a few pictures of that going in and we'll start her up and see if she charges. Woohoo! Wish me luck.
I also just ordered the Pamco Ultimate High Output ignition for the old gal. One step at a time I'm dragging her into the 21st century!

Yet to come, tune up phase, finally.
Front brakes (maybe a caliper rebuild)
Front and rear wheel bearings
Steering head bearings and, and, and,... who knows...
Till next time, Bob

You will like the clean look of hard wiring the plug to the regulator. Till the regulator goes out.

weekendrider said:

You will like the clean look of hard wiring the plug to the regulator. Till the regulator goes out.

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Don't be a cloud on my sunny day! Lol
Actually I never even thought about that. If that should happen, there is plenty of original wiring harness left there. It would be easy to then create a plug in extension.

Yup - be an optimist....an optimist with a plan!

Pete

I didn't appreciate 5twins fore thought either till I had one go bad. It now has a pigtail with flat spades to plug into the OEM socket on the regulator.

Mailman, its soothing to me to accept that the XS's I own are just not completely reliable electrically. It's okay, leaving town with a little good luck needed adds to the experience as well. We must be intune with our machines ! Mano&machine , together for the gamble ! An element of the experience that contributes at the end of the day to me. We don't need no stinkin GPS or ABS ! We like the risk

I'm quite confident about my stock charging system, especially since I upgraded the reg and rec. I don't have an actual voltmeter gauge installed but I do have a color changing L.E.D. charge light that gggGary was kind enough to send my way. It glows a consistent and comforting green now once RPMs get above 1500 to 2K. Before, with the old stock mechanical regulator, it randomly changed between green and orange (less output) at all different RPMs, even above 4K sometimes. I can just imagine the extra stress that was putting on my rotor, what with the constantly fluctuating charging output demand.

K, yes its actually me who's not completely electrically reliable... I give. Sometimes I just remember a song "I'll probably never make it there" but yet I do ..

Jetmechmarty, I like the sound of those "plug in" versions from Oregon. I see it says they are suitable for bikes with separate regulator/rectifier units. Does that include my stock '78SE? That sort of non-interactional electrical installation matches my electrical know how and almost makes the item worth the $271.00 it would cost to get it here to Oz - especially if it can offer electrical reliability.

David Toll said:

Jetmechmarty, I like the sound of those "plug in" versions from Oregon. I see it says they are suitable for bikes with separate regulator/rectifier units. Does that include my stock '78SE? That sort of non-interactional electrical installation matches my electrical know how and almost makes the item worth the $271.00 it would cost to get it here to Oz - especially if it can offer electrical reliability.

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You contact him directly. He should earn the price of admission you're paying. That's what he's there for.