XS2 Wiring Diagram for Regulator/Rectifier from MikesXS

[padgett]

Hey all, Have an XS, possibly TX650 from 72 that I've been slowly rebuilding. All stock wiring wise except for the reg/rec that I decided to chance Mikes with: https://www.mikesxs.net/yamaha-xs650-solid-state-rectifier-regulator-70-79.html

The wiring diagram provided I did my best with, but the bikes running now and it is not charging. Worth noting that the bike was not running prior to me fitting this reg/rec and the stock parts that came in a box were not going to be put on the bike. So no idea whether it had a charging issue prior.

Assuming I'm not the first one to try to put this reg/rec on an XS2, is there an existing wiring diagram floating around already?

 

[Jim]

Just looked at the diagram from MikesXS. It's accurate. If you wired it like's shown from Mikes, it should work.
Fwiw... that wouldn't be the first Reg/Rec from Mikes that's bad out of the box. Happens more than it rightly should in my opinion.

Here's a link to how to troubleshoot charging issues.
https://www.xs650.com/threads/rewound-alternator-rotor.54276/post-584935

Here's the diagram for the '72 and '73 bikes.

 

[padgett]

Thanks, Jim. I've been using that specific diagram quite a bit.

What I don't see on that diagram, and what I was hoping to see in a specific xs2 one for my issue was what to do with the pigtail coming off the stator harness. Theres the main stator plug with the 3 white wires, the neutral switch, then this pigtail that I can't figure out what it goes to. I just have it hanging there at the moment. Continuity-wise it shares with the 3 whites.

Just looked at the diagram from MikesXS. It's accurate. If you wired it like's shown from Mikes, it should work.
Fwiw... that wouldn't be the first Reg/Rec from Mikes that's bad out of the box. Happens more than it rightly should in my opinion.

Here's a link to how to troubleshoot charging issues.
https://www.xs650.com/threads/rewound-alternator-rotor.54276/post-584935

Here's the diagram for the '72 and '73 bikes.

 

[Jim]

What I don't see on that diagram, and what I was hoping to see in a specific xs2 one for my issue was what to do with the pigtail coming off the stator harness.

3 whites= goes to the rectifier. There's no particular order.
Black= goes from the regulator black to the grounded alternator brush.
Green= goes from the regulator green to the other (not grounded) alternator brush.

then this pigtail that I can't figure out what it goes to.

Pics of what you're looking at would help.

 

[padgett]

3 whites= goes to the rectifier. There's no particular order.
Black= goes from the regulator black to the grounded alternator brush.
Green= goes from the regulator green to the other (not grounded) alternator brush.

Pics of what you're looking at would help.

you can see it here:

 

[Jim]

Got it. As you said above, blue is the neutral switch. The yellow goes to the starter safety relay.

 

[padgett]

Alright, i dont feel bad about leaving it alone then. I'm going to go through your list and do the stator and reg tests. I am getting good magnetic pull from the rotor with the key on.
If it does turn out mikes reg/rec is bad out of the box (wouldn't doubt it), whats a reputable place to buy a modern combo box these days?

 

[Jim]

Your best (and cheapest) bet is to roll your own. On a difficulty scale of one to ten, it's about a 3.
Scroll down to comment #2 for your bike.

https://www.xs650.com/threads/diy-reg-rec-5twins-and-jim.55842/

 

[Its been a long time]

Alright, i dont feel bad about leaving it alone then. I'm going to go through your list and do the stator and reg tests. I am getting good magnetic pull from the rotor with the key on.
If it does turn out mikes reg/rec is bad out of the box (wouldn't doubt it), whats a reputable place to buy a modern combo box these days?

Definitely think seriously about what Jim suggests regarding use of a standard three phase bridge rectifier and automotive regulator. It's a low $$$ solution and it works amazingly well. Plus you have the advantage of knowing exactly how it works and future repairs are dirt cheap. And unlikely for a significant period. I would ask for a return on the Mike's part and get your money back.

 

[padgett]

Definitely think seriously about what Jim suggests regarding use of a standard three phase bridge rectifier and automotive regulator. It's a low $$$ solution and it works amazingly well. Plus you have the advantage of knowing exactly how it works and future repairs are dirt cheap. And unlikely for a significant period. I would ask for a return on the Mike's part and get your money back.

Oh i am for sure. Im just kicking myself for giving mikes $120 of my money for a rectifier shaped paperweight. I'm going to try my best to get that going. But more than likely I'm doing what Jim suggested.

 

[Its been a long time]

Oh i am for sure. Im just kicking myself for giving mikes $120 of my money for a rectifier shaped paperweight. I'm going to try my best to get that going. But more than likely I'm doing what Jim suggested.

Good idea to do as Jim suggests. I had never done any electrical work like that before. But I got my 650D charging really nicely with the cheap as chips rectifier and regulator. The whole thing cost me around $40 including making new sub harnesses. And I have the satisfaction of knowing I did it myself.

 

[650Skull]

Hey all, Have an XS, possibly TX650 from 72 that I've been slowly rebuilding. All stock wiring wise except for the reg/rec that I decided to chance Mikes with: https://www.mikesxs.net/yamaha-xs650-solid-state-rectifier-regulator-70-79.html

The wiring diagram provided I did my best with, but the bikes running now and it is not charging. Worth noting that the bike was not running prior to me fitting this reg/rec and the stock parts that came in a box were not going to be put on the bike. So no idea whether it had a charging issue prior.

Assuming I'm not the first one to try to put this reg/rec on an XS2, is there an existing wiring diagram floating around already?

Gotta disagree with that Mike's XS diagram. It is wired for an 80 and later type A regulator for the factory TCI.

Could b you have it wired wrong

Your bike has points. One of the wires to the brushes has to b a black earth wire..

If you go with the SS Reg/Rect here is how an B type reg is wired in a points bike
https://www.xs650.com/threads/wiring-in-a-70-79-combined-reg-rect-to-all-points-model-xs650s.52339/

 

[650Skull]

Just looked at the diagram from MikesXS. It's accurate. If you wired it like's shown from Mikes, it should work.
Fwiw... that wouldn't be the first Reg/Rec from Mikes that's bad out of the box. Happens more than it rightly should in my opinion.

Here's a link to how to troubleshoot charging issues.
https://www.xs650.com/threads/rewound-alternator-rotor.54276/post-584935

Here's the diagram for the '72 and '73 bikes.

View attachment 341961

Am I missing something. This is the diagram from MikesXS for the 70-79 points model bike

This diagram is for an 80 and later TCI bikes

 

[Jim]

Gotta disagree with that Mike's XS diagram. It is wired for an 80 and later type A regulator for the factory TCI.

Could b you have it wired wrong

Your bike has points. One of the wires to the brushes has to b a black earth wire..

If you go with the SS Reg/Rect here is how an B type reg is wired in a points bike
https://www.xs650.com/threads/wiring-in-a-70-79-combined-reg-rect-to-all-points-model-xs650s.52339/

Here's the diagram from the Mikes link the OP put up. Clearly it's a '70-'79 'B' type regulator.

 

[650Skull]

I see where that set of instructions is now. When reading the Reg/rect details there is a link for installation instructions
I followed the link to a PD to installation instructions for a TCI, 80 and later models ,.....,........didn't scroll through the pics......not confusing at all

 

[padgett]

appreciate you all chiming in. Spent some time poking around this issue today and i'm going to write an essay mainly to put my thoughts in order. You can keep plugging away at this with me if you like.

This is the closest to how I wired the bike, and confirmed as such. The 6 pin connector off the stator, i directly spliced into the mikes reg/rec. So the green and black came from that as well as the 3 whites, which all feed into the new reg/rec like in this diagram. My black is grounded as such, red to positive batt, brown is where things get weird.

Based off what I can tell from the xs2 wiring diagram posted above, that brown wire from the regulator also joins up with the two stop light switches, turn signal relay, and probably something else im forgetting. So the brown from the new reg/rec i spliced into that brown wire going to the key switch that also has those other components on it.

Jim's charging troubleshooting doc was great and the stator pull test using feeler gauges wasn't successful for me. Key on/off, no pulling on the feeler gauges or any voltage to the green wire(in my case) to the stator. Cleaned the connections and inspected the brushes and put everything back together, no change. Cleaned up the contact point on the rotor, no change either.

The oddness is that if i turn on something else in that brown wire circuit, like the turn signals for example, i get power to the left brush on the stator. Good pull of a feeler gauge, but not great voltage. On a battery with 12.5-13v I think my best reading at the green wire and left brush when the signals were on was 10v. Turn the signals off, voltage disappears from the rotor.

Obviously not ideal. But I've been staring at this problem long enough so I'm going to sleep on it and maybe the answer will be in my head by morning, usually is.

Thanks again

 

[jaybar6]

appreciate you all chiming in. Spent some time poking around this issue today and i'm going to write an essay mainly to put my thoughts in order. You can keep plugging away at this with me if you like.

View attachment 342029
This is the closest to how I wired the bike, and confirmed as such. The 6 pin connector off the stator, i directly spliced into the mikes reg/rec. So the green and black came from that as well as the 3 whites, which all feed into the new reg/rec like in this diagram. My black is grounded as such, red to positive batt, brown is where things get weird.

Based off what I can tell from the xs2 wiring diagram posted above, that brown wire from the regulator also joins up with the two stop light switches, turn signal relay, and probably something else im forgetting. So the brown from the new reg/rec i spliced into that brown wire going to the key switch that also has those other components on it.

Jim's charging troubleshooting doc was great and the stator pull test using feeler gauges wasn't successful for me. Key on/off, no pulling on the feeler gauges or any voltage to the black wire(in my case) to the stator. Cleaned the connections and inspected the brushes and put everything back together, no change. Cleaned up the contact point on the rotor, no change either.

The oddness is that if i turn on something else in that brown wire circuit, like the turn signals for example, i get power to the black wire on the stator. Good pull of a feeler gauge, but not great voltage. On a battery with 12.5-13v I think my best reading at the black wire when the signals were on was 10v. Turn the signals off, voltage disappears from the rotor.

Obviously not ideal. But I've been staring at this problem long enough so I'm going to sleep on it and maybe the answer will be in my head by morning, usually is.

Thanks again

The generator is working normally. The voltage is 12 volt so the magnet is off, when you switch the indicator on (or any load). The voltage drops so the regulator detects this drop in voltage and turns on the magnet increasing the output of the generator to compensate.
I don't know about the 10 volt on the black wire though, should be 0 volt?, it is a ground wire.

 

[padgett]

The generator is working normally. The voltage is 12 volt so the magnet is off, when you switch the indicator on (or any load). The voltage drops so the regulator detects this drop in voltage and turns on the magnet increasing the output of the generator to compensate.
I don't know about the 10 volt on the black wire though, should be 0 volt?, it is a ground wire.

That does make sense.
Regarding the black wire, I need to revise the above post. I was probing the left most brush and getting 10 volts. The actual black wire and the screw attached to it, not getting anything. You're correct. Right most brush not getting any voltage. The bottom screw that the green wire is attached to also reads 10 volts.

Note the voltage is when something like the blinkers are turned on. Not when the immediate key on as i'd expect.
Sorry about that.

 

[padgett]

I think im going to call the reg/rec from mikes.

Confirmed power is going to the reg rec through the red wire, and brown wire, everything else on the brown circuit works. Good grounds. Nothing coming from the green wire to the stator. So i guess I'll try building my own.

 

[Its been a long time]

I think im going to call the reg/rec from mikes.

Confirmed power is going to the reg rec through the red wire, and brown wire, everything else on the brown circuit works. Good grounds. Nothing coming from the green wire to the stator. So i guess I'll try building my own.

Good decision.