Regulator Rectifier Connector Replacement

[dcarver]

Note - kind of doubt many will ever replace the RR output connector, but just in case, here's what I learned.
Hope it helps someone in the future.
But I'm too lazy to 'translate' all pic urls to make it work here..

"Been noticing a slow RR output voltage droop.
What used to 14.3, 14.4 at 4k rpm with minimal load is now 13.7, 13.8.

Last time I had the RR output connector off, noticed it *easily* came off and on, almost
as if the connector metal fingers had spread open.

So thought I'd start there...

This is a RoadsterCycle harness that goes straight to battery via fuse.
The kit harness comes with connectors installed.
No OEM wiring harness voltage drops using this method."

Pics and full text here.. Feel free to steal, download, molest...
https://candybuttorg.ipage.com/cba/node/1278

[FJRoss]

Nicely done.

[raYzerman]

Very familiar with the Roadster harness and R/R's from the VFR boys.... wondering how that power and ground to the R/R came loose, it shouldn't if it was snug in the first place.... have you had it unplugged/replugged a few times?

[dcarver]

Very familiar with the Roadster harness and R/R's from the VFR boys.... wondering how that power and ground to the R/R came loose, it shouldn't if it was snug in the first place.... have you had it unplugged/replugged a few times?

Yes. Many times actually.
...and, previous connector had a broken 'tang' so would not lock into place. Used Ty-Raps to secure it. And the Roadster wire is heavier gage than OEM, IIRC, so additional mass and fulcrum point?

Then add in 6 miles of washboard road times 5 days a week when working and... well, you know, vibration, unsecured, results predictable.

Will be curious to see if that really was the issue.

[raYzerman]

I'd bet on the frequent unplugging/replugging. Connector is very secure if left plugged in, don't see how vibration could affect it at all.
Roadster's is 12ga. wire, yes heavier than OEM. FJR likely be 14ga. (remembering from my project FJR). VFR is 16 ga. from stator.

[escapefjrtist]

Good information to have DC, thanks!

~G

[dcarver]

Happy with results. 200 miles later, coolish days, max 14.5 low 14.1, with 14.1 occurring when 4 LEDS on low beam, heated jacket on high.