rec/regulator question

[toddyhell]

Can anybody tell me if there is any difference between a suzuki x5 200 rectifier/regulator or a suzuki x7 250 one. Any comments welcomed.

[stinkwheel]

I thought X7s had a seperate regulator and rectifier rather than a single unit?

I do recall them being famously crap.

Sorry to not be of more help.
____________________
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[smegballs]

Got a wiring diagram, it will show whether it is full-wave (yay) or half wave (boo!) rectification. Tbh you can usually make any R/R work within reason.

[stinkwheel]

[smegballs]

[toddyhell]

It's just that my x5 rectifier / regulator was knackered and I bought a x7 rectifier/regulator on ebay was hoping they were the same and manual didn't say they weren't . My trouble now is that when I put the headlight on it stops the charging circuit working. However with the other rec/ regulator being knackered not sure this was happening before. Help!!

[smegballs]

[toddyhell]

Just checked output voltage from the magneto with headlight of and am getting about 30v on green/white wire and about the same on the red/green wire. As soon as I put headlight on voltage disappeared to nothing. Which in turn means nothing going into rec/reg. There are no shorts in charge coils. This could be why I think the rectifier is knackered. Any ideas.

[smegballs]

Okay so I found this.

https://www.suzuki-gt.co.uk/images/Suzuki%20Wiring%20Diagrams/X7%20X5%20Wiring%20Diagram.jpg


I'd run it as one single phase and route the whole lot through a modern RR. What AC volts do you get from the red/green to the green white? If you have a healthy voltage run it into a modern RR like in pic below and then feed the lighting circuits with the regulated 12V DC from an ignition controlled live.

https://i.imgur.com/ySGYeZP.png

That is how I would wire it up, nice heavy cables from the RR straight across the battery terminals (the battery side of the starter solenoid is a good place for the positive lead).

If you want to go down this path (I assume the X5 is 12v??) I'll be happy to answer any questions you might have.

[toddyhell]

Would like to keep it as standard as I can it's just I can't find out why when the headlight comes on the voltage disappears. Thanks for the suggestion though.

[toddyhell]

What 5 pin reg/rec would you suggest for this. Thanks

[smegballs]

Okay mate, I've mapped out the charging system for you.

https://i.imgur.com/3HxAM1g.png

Right first a little theory about RR's to so you can understand it better. With these permanent magnet alternators, the faster they spin, the more volts you get within reason. The regulator works by shorting out the coils - causing output to fall. Basically the more electrical load you put on the alternator, the less it has to shunt. The less it has to shunt the cooler it runs and the happier it is.

Basically Mr Suzuki has cleverly set this up so for the small loads of charging the battery, side lights etc, only one coil is connected to the RR. With a small amount of power being produced for small loads, not much power is shunted and the RR stays happy. Then when you need headlights, the headlight switchs brings the second coil into the circuit giving more power.

So my guess is that you have a short to earth somewhere along the headlight run on the alternator output. When you turn on the headlights to switch in the second coil you are actually switching in a short - thus voltage falls to zero.

Also it looks like the RR earths directly through itself. In that case the RR needs to be nice and clean where it bolts onto the frame, and so does the frame to have a good electrical contact.

To test this, try this picture below with some flying leads just to test it out.

https://i.imgur.com/IOOZ0yj.png

Unplug the RR connection and the alternator connection to isolate them from any potential shorts in the frame. Then connect with flying leads:

Alternator Yellow/green to RR Yellow/green
Alternator Red/Green + Green/White to RR Brown

That should result in both coils putting power into the RR and full output, confirming a short somewhere in the wiring harness.

[toddyhell]

Thanks mate I will try this tomorrow to check that part of the system. Will let you know how I get on. Thanks for the help.

[smegballs]

No worries man, I'll be interested so hear how it goes and whether my cyber-diagnosis is anywhere near the money!

[moonzoomer]

It may be possible to use another reg/rec from another bike and eliminate the headlight circuit completely, I remember fitting honda superdream reg/recs to GS1000/850 Suzukis and Kwak Z range of bikes eliminating the secondary charging circuit, I assume the X5 has a 2 phase ac output ( one switched) so perhaps the Z200 Kawasaki 2 phase reg would be a good choice as they were very reliable thus giving a constant charge on both phases, just thinking out loud here.

[toddyhell]

Tried your theory however no ac volts produced. Tried each coil individualy and getting a rise in voltage at battery when revved. What's going on ffs.