Stator/Generator Wiring - Suzuki GS

[Jaffa-Cakes]

I have a Suzuki GS 550, Mid 70's model which has been converted to a hard tail bobber before my ownership. The wiring loom was a total mess and i'm rebuilding it from scratch, however i'm struggling to identify the correct wiring for the stator and the rectifier.

From the stator i have:
Yellow, which splits; one wire to the regulator and one to the rectifier.
White+Blue; which goes straight to the rectifier.
But then i have White+Green which according to diagrams should be going to the LHS handlebar switch gear, related in some way to the lighting switch... and then returns to the rectifier as White+Red.

Why is it going to the bars?
What switch does it wire to?
If i am having my headlamp on permanent, from the looms Switch Live, am i okay to wire White+Green straight in to White+Red?

Thanks in advance for any help.

Jack

[jjdugen]

Never quite understood 70's / early 80's wiring standards. I presume the older rectifiers and regulators needed some help.
On all the venerable UJM's I just take the three alternator outputs to a modern reg/rec unit. Good luck with the spaghetti in the headlamp, another job for the cutters and soldering iron. (In that I just chop it all out and start again!)
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[Tankie]

which model Gs 550 have you ? is it an E

[Jaffa-Cakes]

Hi Tankie,

The modifications are such that i don't even recognize it. It's a S Reg 1977. Came with a workishop manual for an 'E', but it;s anyone's guess as to whether that's right or not.

Found this diagram after a google search, which seems to be relevant based on wire colours, separate Regulator & Rectifier and also other wiring references which I've been able to match up with what is left of the original loom. And the White+Green and White+Red are the same two colours that i have surplus after board mapping my loom.

[Tankie]

Ok let have a look, give me a min
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[Tankie]

Are you sure this is your model ,this is a stateside model , not uk or euro. this system uses split / balanced charging type system normally seen on machines that run with lights on all the time
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[Jaffa-Cakes]

I haven't found anything else that looks even close, whereas EVERYTHING that i see on that diagram is relevant to the loom on my bike. Even down to wire colours.

I've board mapped my loom, and have two wires left over which head off up the spine of the frame. and this diagram shows the two same colour wires heading to the handlebars.

It's too much of a coincidence for it not to be the right diagram? surely?

[Tankie]

right then, white/red go to the light switch, white green also goes to to same switch.
Just follow each wire run in turn ,a small step at a time
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[Jaffa-Cakes]

But why is the generator connected to the headlamp switch?

I can only guess that it is to provide extra power from the generator when the headlamp is on.

The bike now has an LED headlamp which comes on with the switch live, so i should IN THEORY be able to omit these two wires from my replacement loom?

[Tankie]

Half the switch turns on one phase gen to increase the output when the lights are on, look at the switch diagram. I am now going down the pub for a pint so it you want more info I'll be back by 8
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[Pete.]

I did this but it was 23 years ago. IIRC I used a cb650 reg/rec, or might have been a superdream one but anyway you unbolted the plate that holds the old Suzuki junk and the Honda reg/rec bolted right up to the same holes. Sack the wires that go up to the handlebars they just reduce the load on the voltage regulator when the lights are off, don't need them with the newer reg/rec.

So your three alternator wires go straight into the reg/rec, black and red to battery. I think the Honda item I used had an additional wire which went to switched live I hooked that into the indicator or brake light circuit but make sure you check the donor bike's wiring diagram because some have an additional wire that goes to negative.
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132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Tankie]

I'm back on line now
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