regulator/rectifier combo with points wiring diagram

noid chopperwiringdiagram  regulator/rectifier combo with points wiring diagram

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Write about your XS650.: I got tired of looking for a good diagram that wasn’t completely wrong….so i made one.  simple, easy to read and to the point.  hope it came out as clear as i looks to me.

noid stator screw  regulator/rectifier combo with points wiring diagram

Thanks wayward wayne

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130 Responses to regulator/rectifier combo with points wiring diagram

  1. ALf January 26, 2012 at 7:23 pm #

    answered my own Q. ,, the br/or does go to key switch and brush,,, now the real Q is my bike does not have the br/or going to the key switch,, is that why its not charging?

  2. Danny v January 26, 2012 at 8:07 pm #

    My xs is a 78 and the video is exactly how I did my electric. I have no charging issues at all. If u are having problems charging I would check the stator. I had to replace mine and that fixed the problem. Check out http://www.mikesxs.com

  3. Ted January 26, 2012 at 9:12 pm #

    Tcbros have Put together a wiring harness that takes out all the guesswork if you’re having problems – It’s worth checking out.

    1970-79 Yamaha XS650 Chopper Wiring Harness (points ignition)

  4. ALf January 26, 2012 at 11:09 pm #

    ok thx , ill do that

  5. Ross April 7, 2012 at 12:50 am #

    I have a 1980 XS650 that came with a boyer micro ignition unit. I connected the wires just like the you tube video by cyclechurch666 I think was his user id, anyways I ran the wires like he said but the wires on my pick up coil were cut off. Blk, gray and orange I think are the colors. And it has no points. And now I have no spark? Can any one please help?

  6. sean April 28, 2012 at 7:34 pm #

    I have a 72 xs2 with a reg/rectifier off a 82 xv750 i know the yellow wire from the stator is eliminated but i still have a green and black wire coming off the stator like in the diagram but on the regulator the wire colors are 3 white(to stator) black and red(to battery) and a yellow and brown. Where do they go??

  7. Kris R. May 12, 2012 at 1:56 pm #

    Hey everyone- need some help.

    I have a TC Bros reg/rec combo being installed on a ’78 with stock points ignition. I hooked everything up according to this diagram, and installed a 20 amp fuse between the + battery terminal and the power to the ignition switch and reg/rec. I did not unground the stator, at the instruction of someone at TC Bros. But, I’m still blowing the fuse whenever I flip the key. Any ideas? Is it possibly related to the grounded stator?

  8. Danny v May 12, 2012 at 3:32 pm #

    Don’t listen to TC choppers. Unground it

  9. R. Weide May 14, 2012 at 4:41 am #

    I bought a point ignition engine to replace my other xs engine. My wire harness is ok, so do i only have to unground the brushes with te screws and rearrange some wires in my wiring?

  10. R. Weide May 14, 2012 at 4:43 am #

    Additional to my post above: my other/old engine was an electric ignition engine.

  11. Danny v May 14, 2012 at 7:35 am #

    On January 25 I added a YouTube video on this post. I followed it and it worked perfectly.

  12. mike August 10, 2012 at 5:41 pm #

    i am` trying this attached wiring diagram however the 3 nylon screws i need to unground the brushes does not look the same as the picture, i have 2 different wires it looks like a blk. and brown and they are kiddie corner from one another not next to each other which color gets the last nylon screw??? i have a 78 xs

  13. pete bailey August 11, 2012 at 12:16 pm #

    look closely and you will see that there is only two wires to unground so you only need two plastic screws, the other screw is on the holder and does not need to be ungrounded.. these wires are connected two the brushes [only two brushes]
    usually the two wires are one green and one black.. hope this helps you…….

    • mike August 11, 2012 at 7:31 pm #

      thanks pete, that makes sense, but the schematic shoes the green wire with a metal screw in it? is the illustration incorrect? thankyou for your response

  14. nick kolasa August 11, 2012 at 3:42 pm #

    so I’ve had my bike wired exactly as shown above with new combo r/r, new stator rotor assembly and to new coils. after about a week of riding i notice my bike was continuously missing. come to find out i blew one of my coil packs up. does anyone no why this could be happening? i replaced it and it happened again after about another week or so. i went threw all of my wires and nothing is loose or shorted.

    • pete bailey August 13, 2012 at 3:25 am #

      Nick the only thing i can think of is that the volts are too high on the feed side of the coil. Also try not to use the old loom [harness] it is thirty years old and fucked, always use new wires when you can. Pete

  15. nick kolasa August 11, 2012 at 3:43 pm #

    i have a 72 xs650 btw

  16. Nick Kolasa August 14, 2012 at 9:17 am #

    So do you have any suggestions on how to go about fixing this issue? Also most of my wiring is brand new except for the wires going from the stator to r/r assembly.

    Thanks for the quick response.

    Nick

  17. mike August 15, 2012 at 1:14 am #

    I am ready to try this wiring diagram but before i hook it up to the battery i need to make sure of the plastic screw placement, i have a 78xs and the 2 wires on the brushes on mine are kiddie corner from one another not next to each other (one blk and one that looks to be brn.) in the picture it appears the blk. has a plastic screw and the other a metal screw, pete had posted that both wires need plastic screws. could anyone give me a little more clarity on 1) is pete or the illustration correct? 2) why are my 2 wires on opposite corners of the 4 screws? 3) if the illustration is correct do i just need to unground the blk. wire with a nylon screw? thanks

  18. pete bailey August 15, 2012 at 4:00 am #

    the first two xs650 bobbers that i built i did not unground the brushes and they are still going strong after at least four thousand miles, both these bikes had the same system as you have. dont forget that yamaha didnt unground the brushes. I would start the bike and put a meter across the battery terminals and if you have steady charge of between 13 and 14.8 volts then you have got lift off…..good luck..

    • Cd August 22, 2012 at 1:01 pm #

      Could you email me that wire diagram plear

  19. Kris R. August 15, 2012 at 10:28 am #

    For what it is worth-

    I wired my ’78 XS with this diagram and a TC Bros reg/rec. With the brushes un-grounded, the charging system would not charge the bike. I had to push the bike home 30 blocks on four different occasions. I re-grounded the brushes and it worked fine after that.

    I really think the stator brush ground discussion is based on your reg/rec, not your bike. I’ve heard people who un-ground their brushes mention using a reg/rec off of an older bike, which (I suspect) is the reason for the un-grounded brushes. If you’re using a modern reg/rec for the XS 650 (TC Bros, Mikes XS, Hugh’s Handbuilt, etc.), I’m fairly convinced you don’t need to un-ground the brushes.

    I’ve since installed a Hugh’s Handbuilt PMA and don’t have to worry about this anymore.

  20. pete bailey August 15, 2012 at 10:46 am #

    i think your right, it is the reg/rec that makes the difference, always use a modern reg/rec and you will probably have a better chance of getting it up and running……..

  21. mike August 15, 2012 at 7:37 pm #

    Thankyou for so much valuable info. i have a 81 xj650 reg/rec from what i here i would be better off to unground the brushes and check voltage when it is running i would love to leave it in stock configuration but from what i gather this would probably not work with the older reg/rec
    my only other question is why is just the blk. wire ungrounded? i think it makes sense as you said pete to unground both wires.
    thankyou chris also for your comments very useful info and if i fry this reg/rec i will get a more modern one.
    i guess i will try it with the blk. wire ungrounded and go from there
    i will not be home until friday so any last comments will be greatly appreciated before i give her a try.

  22. Kris R. August 16, 2012 at 10:36 am #

    Something I forgot to mention in my previous comment: when I grounded my brushes with the TC Bros reg/rec, I connected the black wire coming from the stator to my frame/negative battery terminal. The black wire coming from the stator is the stator ground, and should not be connected to the red power wire (as this diagram shows) if the brushes have the stock metal ground screws in them– unless you want to blow fuses or melt down your electrical system.

    Mike- there is no way for me to say if you should unground the stator or not. I think it depends on the way that reg/rec was designed. If the reg/rec has the same wires that a stock XS reg/rec or a modern XS reg/rec has, then (if it were me wiring it up) I’d wire it up with the brushes grounded and the ground wire from the stator going to your main ground. Make sure to wire in a 20 amp fuse between the positive battery terminal and the ignition switch and reg/rec. The fuse will save you if the wiring is wrong. Run the bike, put a voltage meter on it and see what your charging voltage is like at 3000 rpms or so– should be 13.2v-14.4v. If that setup doesn’t work, try this diagram with the brushes ungrounded.

    Good luck.

    • mike August 16, 2012 at 8:44 pm #

      thankyou kris connecting the blk stator ground to a red was puzzling to me to but i figured if the blk stator wire was ungrounded (nylon screw) it was ok (somehow)
      so if i try it your way (do not worry i would NEVER cry to you if it did not work) i think we have all had setbacks building bikes, but it does leave another question, in the diagram the brown from the reg/rec splits, one going to blk stator and one to ign. if i run blk. stator wire straight to ground does the brown reg/rec just go to ign.? i REALLY appreciate all the input.
      the wire color on my reg/rec match up with the connector coming off the motor
      thanks for your time

  23. Kris R. August 17, 2012 at 12:50 pm #

    Yeah, brown wire on reg/rec goes to the switched power. Then you also have a red wire which goes to the positive battery terminal.

    Good luck.

    • mike August 17, 2012 at 8:30 pm #

      thankyou so much for your input and suggestions , i think i will put the metal screws back in, put the fuses in and see if i can get some spark. i will post the results

  24. mike August 19, 2012 at 10:13 am #

    i was finishing up the wiring to see if we can get some spark , i checked the wire colors for the stator to make sure i was grounding the blk to batt. when i discovered the 2 wires were green and brown (no blk.) so i ask (yet another ques.) which color is considered blk.? i assume it is the brn. since green is going straight from reg/rec to stator thanks

    • Kris R. August 19, 2012 at 11:56 am #

      Not sure. Figure out which one is connected to the stator brush grounds. Pop off the little stator cover and see which color wire is connected to the three brush ground screws.

    • pete bailey August 20, 2012 at 2:40 am #

      green is usually one of the brushes……..

      • mike August 20, 2012 at 6:24 pm #

        as i had mentioned in an earlier post the illustration above shows the 2 stator wires next to each other (as does another motor i have) and one of those wires is blk.
        the engine i am using has the 2 wires on opposite corners from one another each one is holding the springs down for the brushes so there is a wire on each brush (i hope that makes sense) this is my first yamaha project i was into the hondas but i have the 650 bug so i have 2 650s and 4 motors (1 for parts) but this is the best engine so i really would like to use it.
        so i guess i have to try and figure out this odd ball with all of your wonderful help.
        i do not have a shop manual for the 650s yet (but i will) i was going to see if the brn. off the stator goes to blk. after the connector. i do not have to much of the stock wiring harness so i do not have much to go by. thanks for all of your help

        • mike August 22, 2012 at 7:40 pm #

          so i guess i start over a little, when i bought the bike i was told it was a 1978, upon further research in 1980 they changed the stator wiring which includes a brown and green wire at the stator brushes so now i need to find a schematic for the different stator configuration, i am so sorry for wasting your time, i will post my end results hopefully to save some one else some time, any thoughts?

  25. Kris R. August 23, 2012 at 10:33 am #

    If it’s a 1980, it should have a TCI electronic ignition. In that case, I’m not sure how the wiring diagram would look, as my bike has a points ignition. This diagram is for a points ignition, as well.

    • mike August 23, 2012 at 8:48 pm #

      Well i do have points, and my stator has a green & brown from the stator and those wires are in opposite corners(of the 4 screws) each holding down a separate metal strip (spring retainer) so if a 1980 is tci then someone must have put a 70-79 top end on a 80 btm. end (wont that stink) i guess i will keep trying to find answers

  26. pete bailey August 25, 2012 at 4:23 am #

    there should be little or no difference if you run points or electronic ignition, an alternator is an alternator they are all the same..you should have three wires that are white or yellow they are your field magnets, there might be a plastic covered yellow wire coming from your alt this is not required [cap it] you should have a green wire and a black wire coming from your brushes, a red wire and a brown..some reg/rec have six wires some have seven both will work if correctly wired.dont for get your exiter wire to the alt…….

    • mike August 25, 2012 at 6:26 pm #

      i agree, and i know i do not explain things well, my brush wires are green and brown there is no black wire. the other difference about my brush set up compared to the picture above is the 4 screws involved with the brushes my brown and green wires are kiddie corner from one another not on the same side as in the picture, it is a change that supposedly was done in 1980 and has something to do with the way they grounded the stator so i do not know if i should ground or unground this setup. i just googled to ground or unground stator wires for xs650 and found out about these changes thanks pete

  27. mike August 25, 2012 at 8:22 pm #

    well it is me again, and it looks as through i have a 1980 btm. end and a 70-79 top end (points) the 1980 stator is already ungrounded hence the brown and green brush wire colors and it appears i can just run the brown to ignition green to reg/rec. and wire the rest per above schematic. so thats what i will try. i will post results (crossed fingers)

  28. mike September 20, 2012 at 8:41 pm #

    in closing the bike had great spark and ran great, took it up and down the street, tried to check the running voltage but all i would get was varying readings (jumping around) but when i turned the motor off it was still at 12.47v

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  30. thefatguy February 25, 2013 at 12:46 am #

    I have a rec/reg combo from I don’t no what. It only has 3 white,red,black, and brown….there’s no green on this rec. So my question is what am I gonna do with the green wire from the brush? I’m using a simple ignition from auto parts store. Can I just run it to the ignition post on the ignition with the brown and black wire?

  31. pete bailey February 25, 2013 at 4:44 am #

    remember that the two wires from the brushes are pos and neg, so there is a live coming from one and earth from the other..

  32. thefatguy February 28, 2013 at 3:13 am #

    So Im guessing the green wire is going to be my negative since the black wire is going to the ignition…..thanks Pete I was just over thinking the whole thing…..thanks for the help

  33. mike March 30, 2013 at 8:07 pm #

    Hi, i have followed this schematic and the bike runs great and all the lights, horn brk. lights, ignition work as they should.
    but after riding i have 12 volts at the battery but if i let it sit with ign. and everything off i get a draw on the battery down to 1volt after about 12 hours. any help out there.
    thanks

  34. Jake g August 25, 2013 at 10:17 pm #

    Hey guys just wondering if you can help? I have a 1980 xs 650 with points and I’m trying to wire up a regulator/rectifier I bought of eBay. From the stator my bike has 3 brown wires 1 green 1blue 1black. The new regulator has 2 plugs 1 plug has 3 white 1red 1black and the other plug has 1brown 1green. Can anybody tell me what wires to connect? Cheers jake

  35. Willem February 28, 2014 at 11:46 am #

    Hi guys,
    English is not my native language but I’ve tried to understand the discussion.
    My question is also about the green wire. My new regulator has six wires instead of seven.
    Can I just not usethe green wire? Or do I have to ground it?

    Can anyone help me????

    Thanx,
    Willem – Holland

    • pete March 1, 2014 at 4:01 am #

      green wire goes to one of the brushes on the stater …..

      • Willem March 1, 2014 at 6:23 am #

        Thanks Pete, the green comes from the rectifier in the old situation. The new regulater/rectifier doesn’t seem to have a green wire connection. Can I put it on the battery or together with the brown wire I have?
        Or can I do without the green wire.

        • pete March 2, 2014 at 4:35 am #

          two wires come from your brushes that are in your stater one is pos/ and one neg..if you have not got a green wire from your reg then i would try and see if you have a spark,[ kick it over] if no spark then ground the green wire then try again….