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Second XS650, 1977 Standard
- Thread starter FrankS
- Start date
Yes, I'm not a fan of those aftermarket combined units. They're expensive and most are Chinese junk.
I like the Auto Reg + bridge rectifiers, have built one for myself. Also know going this route is not as cheap as if living in the US. Cost of postage and local, (if available), availability and cost can b double or more than in the US and that is without postage. Seems, and there have been some reports, the cheap Chinese SS Reg/Rect have failed causing problems. How wide spread is anyone's guess, but there have been Failures.
I put this together because there are different ones on the market and the wiring colours can differ from different manufactures. Wiring instructions from MikesXS at the time of writing this was wrong, (surprise surprise). I am not advocating for one or another. Information to help sift through the variations.
https://www.xs650.com/threads/wiring-in-a-70-79-combined-reg-rect-to-all-points-model-xs650s.52339/
Can buy 3 Phase Bridge rectifiers which is advocated mostly these days. When i built mine i used 2 single phased Bridge Rectifiers in line. This also gives me a spare Phase, (spare white wire), i can swap into if one fails.
Nothing is fool proof, there has been reported failures from bridge rectifiers as well, a couple but it happens.
Pics of my set up that i put under the battery box as per the original
I put this together because there are different ones on the market and the wiring colours can differ from different manufactures. Wiring instructions from MikesXS at the time of writing this was wrong, (surprise surprise). I am not advocating for one or another. Information to help sift through the variations.
https://www.xs650.com/threads/wiring-in-a-70-79-combined-reg-rect-to-all-points-model-xs650s.52339/
Can buy 3 Phase Bridge rectifiers which is advocated mostly these days. When i built mine i used 2 single phased Bridge Rectifiers in line. This also gives me a spare Phase, (spare white wire), i can swap into if one fails.
Nothing is fool proof, there has been reported failures from bridge rectifiers as well, a couple but it happens.
Pics of my set up that i put under the battery box as per the original
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https://www.xs650.com/threads/phosphoric-acid-for-rust-on-chrome-parts.58237/
This thread has a bunch of responses on acid rust removal and where and what to buy.
This thread has a bunch of responses on acid rust removal and where and what to buy.
Plaid double knit slacks, mullets and disco were popular once too.
There’s no accounting for taste. I just pointed to the fact, and you have reinforced it. Some people still like disco and my youngest daughter keeps her younger son wearing a mullet. (He’s 5, so she’s getting away with it.)
Yeah, I look back on what I thought was "cool" and laugh.
FrankS
XS650 Addict
So yesterday I cleaned up the master brake area on the handlebar. I was able to remove the heavily destroyed screws that hold on the cap of the brake reservoir. After an exterior cleaning, I noticed that the master brake piston operated well, and I had hopes that the brake caliper would be as accommodating.
Today I tackled the front brake by first attempting to simply bleed the brakes, and it worked! Now I have fully functioning front and rear brakes. Then I dismounted and cleaned up the insides of the hand switches - left and right. They were both very dirty and filled with crud.
Emboldened by my success so far, I decided to look into the electrical issue. When I first attempted to hook up a battery, there were sparks (current flow) with the ignition key off and the single 20 amp fuse blew. It was a glass cylinder type. I replaced that with an auto type fuse holder that I used on the '78 Special xs650. Following Jim's procedure to find where the short was, I unhooked everything except the ignition switch connection, turned on the key and proceeded to reconnect connectors until the fuse blew.
The culprit was the rectifier.
Now I would like to replace the rectifier and regulator with a modern combo unit. For my Honda cb750, here was the simple replacement carried by vintagecb750.com that I used. Is there a similar source with a replacement reg/rect for the 1977 xs650?
Today I tackled the front brake by first attempting to simply bleed the brakes, and it worked! Now I have fully functioning front and rear brakes. Then I dismounted and cleaned up the insides of the hand switches - left and right. They were both very dirty and filled with crud.
Emboldened by my success so far, I decided to look into the electrical issue. When I first attempted to hook up a battery, there were sparks (current flow) with the ignition key off and the single 20 amp fuse blew. It was a glass cylinder type. I replaced that with an auto type fuse holder that I used on the '78 Special xs650. Following Jim's procedure to find where the short was, I unhooked everything except the ignition switch connection, turned on the key and proceeded to reconnect connectors until the fuse blew.
The culprit was the rectifier.
Now I would like to replace the rectifier and regulator with a modern combo unit. For my Honda cb750, here was the simple replacement carried by vintagecb750.com that I used. Is there a similar source with a replacement reg/rect for the 1977 xs650?
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FrankS
XS650 Addict
Would this be the best choice? Or is there something else to look at? I'm hoping for simple plug and play. Building my own like 650skull is beyond me.
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https://ricksmotorsportelectrics.com/Universal-Style-Rectifier-Regulator-10_504
https://xs650direct.com/products?make=22&year=13&model=69&category=95&page=5
The same thing you bought for your Honda is available for your XS650D. I have no experience with these. The second link is in Canada. I'm sure you will be given links to build your own. I haven't done that either. I'm just responding to your ask. Based upon my experience with MikesXS, I would probably choose either of these first.
https://xs650direct.com/products?make=22&year=13&model=69&category=95&page=5
The same thing you bought for your Honda is available for your XS650D. I have no experience with these. The second link is in Canada. I'm sure you will be given links to build your own. I haven't done that either. I'm just responding to your ask. Based upon my experience with MikesXS, I would probably choose either of these first.
FrankS
XS650 Addict
Thank you Marty. Ordered it along with a few other bits.
Today all I did was remove the rear wheel. Not as easy as you'd think. The axle would not clear the mufflers. I had to totally remove the fasteners between the exhaust system and the frame/motor. Then the axle needed much persuasion to come out. Guess it had been in there for a while.
Today all I did was remove the rear wheel. Not as easy as you'd think. The axle would not clear the mufflers. I had to totally remove the fasteners between the exhaust system and the frame/motor. Then the axle needed much persuasion to come out. Guess it had been in there for a while.
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Can remove the rear wheel without touching the mufflers, as long as the chain has a joining link.
Loosen the axle nut and adjusters. Roll the adjusters down exposing the bolt that holds the swingarm blocks. Push the wheel forward to give the chain some slack. Remove chain link, break the chain
Uncouple the brake stay and adjuster
Undo the shocks from the swingarm to let it drop to get the wheel out from the guard
Remove the swingarm block bolts, remove the blocks and the rear wheel and axle slides out the rear in on peice.
Pics of my Suzuki. It has a disk brake rear but the principle is the same
Loosen the axle nut and adjusters. Roll the adjusters down exposing the bolt that holds the swingarm blocks. Push the wheel forward to give the chain some slack. Remove chain link, break the chain
Uncouple the brake stay and adjuster
Undo the shocks from the swingarm to let it drop to get the wheel out from the guard
Remove the swingarm block bolts, remove the blocks and the rear wheel and axle slides out the rear in on peice.
Pics of my Suzuki. It has a disk brake rear but the principle is the same
Attachments
FrankS
XS650 Addict
Excellent advice! This is exactly why experienced experts are so valuable! Thank you so much!!!
FrankS
XS650 Addict
Disappointment: Got a note about my parts order from xs650direct that the reg/rect is out of stock. That was the primary reason for my order.
http://www.siriusconinc.com/products
This one is also Canada. I looked up the ESR 320 and found application to several motorcycles including XS400 and XS650 Specials. I think it’s what you’re looking for.
I’ve had several positive experiences with this vendor.
FrankS
XS650 Addict
Thank you sir! I looked and believe that one is a type A meant for later year xs bikes.
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When you put one of these reg/recs together, you're really not "building" it, just wiring it up and making mounting plates for the two components. Honestly, it's not that difficult, and if you're going to own and ride old bikes, you are going to have to learn how to do some wiring and wiring repairs. Invest in some tools (proper crimpers and an assortment of crimps and connectors) and it's pretty easy.
I will second those comments. I went from a standing start to installing a 3 phase bridge rectifier and automotive regulator to my 650D. I made new sub-harnesses and a mounting plate for the regulator. The rectifier mounted exactly the same way as the Yamaha one. A satisfying project to do that considering I hadn't done anything like that before. I just based what I did on the information found on this website.
I now have a sound and hopefully reliable charging system that cost me less than £25 all done. Even better, I know exactly how it all works so future maintenance, should it be required, will be simple.
Agreed. That reg/rec how-to thread was written to give a common sense explanation of what's going on and instructions also written to be easy to understand and follow. Its just needs the very basic of mechanical skills. The bonus is it's a hell of a lot cheaper that "store bought."
Exactly. I couldn't have done the job without that giving me the confidence to do so. It's more difficult here in the UK because we can't really get the recommended regulators here like you can in the USA. I got a recommendation from someone regarding what to buy here, it works fine. It's easier for you over there, just use what is recommended in the how to thread.
