Sep 14 2009
regulator/rectifier combo with points wiring diagram
- 85
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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.
Thanks wayward wayne
Not to throw rocks, Wayne, just suggestions – what about low beam/high beam on the headlight and stop/tail on the rear light? That won’t complicate it much. Useful info on the charging system, thanks.
Thanks wayne. Sure some will find it handy.
Not trying to piss on your site, Ted, since your cross-advertising with the 650rider site; There are some great diagrams that include a very basic chopper diagram and one that includes signals on 650rider in the Vault section of Forums.
Thanks to Wayne for posting this. It’s a great, very simple diagram to get you started, and fairly easy to add some features from there. Starting with this basic schematic will help a lot of guys that feel overwhelmed by the seemingly incomprehensible maze that is the stock schematic.
Great info…wiring is always the biggest nightmare.
I went nuts in the past, I could never find a diagram with the same colors that were on my bike. These are the colors on every xs I have looked at! Thanks
Note
1.reg/ rec combo: dont connect Positive until you are done(prevents causing harm to the reg/rec).
2. 20 amp fuse is needed on the HOT going to ignition.
what happens if you do not unground the stator?
what happens if you dont unground the stator?
if you dont unground the stator brushes it wont charge, probably burn out your reg/rect. and i chose to put in fuses after the switch. if you put one before the switch and it pops you have a dead motorcycle. if one pops after the switch you can cannibalize a fuse from something else like the lights to at least get you home. i always forget my fuses on the road.
Wayne,
1 st question using your wiring diagram does the battery need to be grounded to the frame?
2nd question, the connections at the ignition switch? I dont have the stock iginition, what type would you recommend and connected how?
Thanks , Mig
Another question does this wiring set up work if I’m running a pamco single coil? Trying to set up the single pamco coil with points ignition?
Thanks
Mig
Hey,does the diagram only the points setup?I have a 72 motor with a dyna electronic ignition.I have a older seperate regulator and seperate rectifier.I want to go to a combined one to clean everthing up.I noticed you said it has to be ungrounded?The original yamaha diagrams shows the stator grounded.Ive wired bikes before but since i read your post im sorta gun shy on burning up a virago combined unit until i know for sure.thanks
robert
I bought a rectifier only through mikesxs.com. if i wont kick only do i need a regulator also?
@ danny you will need a regulator/rectifier for a functioning charging system.
hey if you can not get your 4mmx.7 nylon screws 10mm long go to google search and put in mcmastor carr the part number is 94175A315 the phone 609-689-3415 hax screws
wher can i find a regulator/rectifier combo like the diagram
you can get them on ebay. its cheaper usually if you look one up for an xj550 650 750. same unit but because it doesnt say xs650 its half the price. and yes you can use the rec/reg setup on non points ignition systems, just follow the charging system in the diagram. ignore the points. yes the stator has to be ungrounded. The stock wiring diagrams dont account for the mismatched parts were putting on these things. if you dont unground the stator it will burn out your reg/rect very quickly. done it, had to buy another one. i also found that number 6 (i think) nylon screws at any hardware store work great. been running them for 6 months with no problem. The battery does need to be grounded to the frame, kinda forgot that, whoops. you can use a toggle switch for the power but i like to use an actual universal ignition switch from the autoparts store, they’re cheap, have keys and have the option of running a starter off of them. hope that cleared it up, havent check on this in a while.
Anyone have any extra nylon screws they will part with. I will pay the shipping.
I can’t get them locally & I hate to buy a bag of 100 or more when all I need is 3.
Thanks
I found nylon screws M4x.7x10MM thru Grainger part number 4DFA4 they are a phillips pan styled head.
Does anyone know what part of the ignition switch the reg./rec red wire ties into (ie: power in, ignition, ACC, or start)? Any help is greatly appreciated. ejnogaski@yahoo.com
I apologize. I don’t mean the red wire from the reg./rec. I can see from the diagram above that that wire goes to the positive battery post. I’m talking about the brown wire from the reg./rec and the black wire from stator connection. Again any help is greatly appreciated.
I didn’t mean the red wire from the reg./rec. I see that that wire goes to the positive battery terminal. I’m talking about the connection of the brown wire from the reg./rec and the black wire from the stator.
@ EJ black gos to ground red goes to positive on battery terminal Brown goes to stator.
http://www.xs650chopper.com/wp-content/uploads/2009/09/noid-chopperwiringdiagram.jpg
Not sure what you’re really asking, but the best thing I can tell you is to take some pictures and post them up on http://xs650temp.proboards.com/index.cgi some of the guys on that site have been riding and working on the xs for over 30 years.
I have a 1982 xs 650, will i have to swap the screws with nylon on this motor? will this diagram still work for me? please help! ahhhhh!
Mike this diagram will work for you and your bike. click on the diagram blueprint and it gets bigger.
This might be a stupid question but is the coil picup on my 82 replacing the points? do I need a seperate condensor for that?
where do I hook the picup coil wires to???
ok got the charging system wired up and im pretty sure its right. the only problem im havin now is getting my spark back to the plugs. I have a red wire a grey wire and a black wire coming from the pickup coil. I hooked the red and grey up to the coil sides and the black wire to ground. I also fed the red side power and im not getting any spark. Can someone Please help me? Whats Wrong with this?
Im also having exact same problem< no spark? Will somebody help?
i am having a problem with my charging system the where the black wire from the stator and the orange wire from the reg,rectifier connect and go to the ignition as soon as i turn the key over my orange wire smoked like hell and melted away. is this a problem with ungrounding the stator or did i hook it up wrong to my key switch? i am 4 inches of melted wire away from getting the bike going, somebody please help me!!
need to no if i can go bare bones with my 81 special with this i dnt think so not the same wires and more if any can help i need this diagram to get her running
have an 81 with elc. ing. not getting spark to plugs checked ohms on the timing eye was good &coils prim. good but sec. was 28000 need new coils or what ? ps i rewired bike with book wire specs.
All these issues are hitting close to home for me. I have 1978 xs and am running a solid state reg/rect. from mikes xs. Mine has an orange wire and a blue wire that Im confused about. Which one gets switch side power? Also my fuse blew when I threw the swtich. So I switched the wires around, but no charging and ruined my battery. I am assuming it means ungrounding brushes. If anyone knows EXACTLY how to run these two wires please get back to me asap. I dont want to install another reg if the one i have is ok. Thanks for the help….oh I have the pamco high output as well so If there are specifics reguarding the use of both please clarify.
To Blaine regarding the wire colours…Orange is Green and connects to stator. Blue is Brown and connects as per the diagram above. Hope this helps you. It cost a brand new battery and regulator/rectifier for me to find out.
To Tom, I’m presuming you have the 75-79 regulator/rectifier from Mikes Xs in which case the orange lead from the regulator connects to the “green” on the stator. On these aftermarket units the orange is green and blue is brown. I think you are also confusing the brown in the above diagram with orange.
is it comn for ur pic up coils to go out and can i ghange bac to points if i have a elec ignition
im having the same problem as tom, as soon as i turn on the ign. the Black wire from the STATOR (not the black from the rect.) gets hot fast and smokes. anyone have an idea why that is?
Having just bought back my old XS that i chopped 22 years ago I was having nightmares about the wiring! Not any more thanks to all the posts on here! GO GUYS!!!!!!!!!!!!!!
Thanks again duded!
“just follow the charging system in the diagram. ignore the points” Wayward Wayne can you elaborate please? Do I just run wires from the condensor to the coils for an electronic ignition bike?
Mike did you ever get your charging system working for your 82′ xs650? That’s what I have as well and need to know. Thanks
I’ve have a problen . My stator cables where cut in half so the colors in the cables don’t exist anymore . My cuestion is …the rotor inner ring is positive or goes on ground? any body knows about that?
http://www.xs650chopper.com/2009/06/xs650-charging-system-how-to/
thank you for the diagram it saved my life……
i have a 1980,i rewired it,{ele ignition}now no spark,both wires going to the coil (red,orange) are hot when i turn on key,is this right?
Hey I have an 81 xs650, I need some help!!!! I’m having trouble wiring the stator, I have watched the video and followed the diagrams, but still don’t understand where the 3 wires from the stator hook up (Orange, grey, & black) I have a pamco ignition running headlight and tail light and kick start. The rectifier regulator is from mikes xs 7 wires ( red, 3 whites, green, black, brown, and black so I also put the nylon screws in. It idle fine but as soon as you shift to 1st and take of it blows a fuse anyone have answers?
Thanks
Wade
Where to look, I have a 1980 xs. I had it wired and running for about two hours.Then all the sudden I lost power.My buddy had another Rect. laying around so I changed that and had no luck. Then he said its probly the stator. Started to take that off and noticed one of my brushes was worn out. Changed that and charging system worked. Went for 10 min ride and power went again. I just heard about ungrounding brushes so i did that. Tried it , bike started but in seconds lost power and died. You think I blew my rect? Im just wondering if I would have ungroundrd my brushes if id still be riding. Can anyone PLEASE Point me in the right direction?
@ Wade – The best advice I can give you is to buy a meter so you can sort out the wires. ( it’s hard to go by wire color alone) you need to be able to test each wire coming out. With that said, the 3 whites go to your alternator. red + black -. Pick up a book on motorcycle electronics. Then, you’ll have a basic understanding and will be able to wire your bike no problem. Just understanding how a meter works will give you a huge advantage in diagnosing your bikes electrical issues.
@ Wes – From what you have described You are definitely going in the right direction with testing each electrical component. Like I mentioned above, a meter is invaluable in diagnosing electrical issues. you can pick up a meager for $9. It sounds like you have 1. a failing charging-system or 2. electrical short or 3. failing battery. Pick up a meter and start testing each component starting at your charging system.
Here’s how to diagnose your charging system >
http://www.xs650chopper.com/2009/06/xs650-charging-system-how-to/
Thanks Ted. It was a electrical short. I got it all squared away and she runs GREAT! Its good to know there is still a few good people willing to lend some advise to a fellow biker in need.LONG LIVE XS 650 CHOPPER.COM!!!!!!
Thanks for all the info. Trying to finish my first chop and down to the electrical. Bought Mikes reg/rec and having same color code issues. Made a schematic but not sure how to upload for review. Would love input from all.
Can anyone tell me what gauge of wires are used. Power? Ground? and accessories? I have to pick up a few length and wanted to make sure i get the right stuff. Thanks for all the help so far. This diagram looks like it will help!
I have a thought about this diagram concerning ungrounding the brushes and the reason to do so. After cross referancing this diagram with another I noticed a hot wire going directly from the stator to the ignition switch and another from the stator to the reg/rec.. if the regulator regulates the voltage coming from the stator that is allowed into the system wouldn’t this contradict the reason for the reg/rec all together? Could this be the reason that ungrounding the brushes is necessary? In another diagram I found this wire (from stator to ign) is not there……the only hot wire is from the stator to the reg/rec……then splits to battery And ignition switch. Would this option eliminate the need to unground the brushes? Its just a thought….just wondering what all of you think. Thanks for the diagram….just wanna make sure I get it done right without burning out parts that I can’t afford lol.
One other question…..for those that are are running this exact diagram including the ungrounding of the brushes…..have you had any issues? If not how long have you been running this system? Thanks again for the input…..your help is invaluable.
you can get the nylon screws at home depot or lowes in the specialty hardware bins. Just an FYI
hola mi bicicleta no tien los 7 cables le falta el cafe necesito un diagrama para esecorectificador quien me pude ayudar saludos de mexico
amigos saludos chihuahua mex necesito de su ayuda quien me puede enbiar un diagrama de un regulador y rectificador combinado de 6 puntas pera puntos su
ayuda es inbaluable gracias
do you have to unground the brushes only if your reg/rec is solid state or do you unground the brushes no matter what reg/rec you use?
Ted, i have a 76 xs650 with a reg and rect with points ,but they’re not a combo unit. will this wiring diagram still work.need to get some sort of wiring going.
Brian
i have a 83 yamaha xs650. and I will be working on the wiring this weekend. i still have all the factory plug ends and i bought a 8 pin wiring harness from tc. bros any usefull input would be greatful
anyone know how to wire up reg rec with six wires, also six wires coming from alternator, got boyer elec ignition, help………….
i have wired by bike by the diagram above. i ungrounded the brushes and when i turn on the ignition i blow the fuse between the reg/rec. i put in a bigger fuse and it doesnt blow but i still dont pull a charge. does any body have any ideas? please help
i mean the 10 amp fuse between the reg/rec and the positive terminal on the battery
dont forget the exiter wire from the switch to the alt.
you must run a live wire to the alt to magnetise it, because it aint a permenent magnet alternater…….good luck…
i have a live wire from the switch to the brown from the reg/rec that also runs to the black from the stator still wont pull a charge.
i have biult two xs650 bobbers and have wired them the same as you have, and i did not unground the brushes, both bikes are doing well, BUT i have just finnished biulding an xs2 with points, now this is [as far as i can see] the only one you need to unground, then wire up to six wire reg/rec….OH yea i fitted boyer branson to this one.. I think you might need need to get your stator and rotor checked out….
you wired it like the diagram above but didnt unground the brushes? I read that that will burn up your stator.
What one do you think you have to unground? per you post on the july 3.
on the models with combined reg/rec you are really wiring it up the same as yamaha wired it up, so why unground the wires from the brushes, [it was ok for yamaha] now if you are wiring an xs2 or a points bike with seperate reg and rec then ungrounding is a must….as i said both my bikes have done well over 3000 miles and seem to be fine with out ungrounding the brushes…I am not an electician but i can only say what has worked for me
So I have been battling charging issues for two months, first tested rotor, it was bad, replaced it then tested the stator checked out ok, then I realized my combined reg/ rec from mikes xs burned up in the process “incorrectly wired possibly” , so I then replaced that with a reg/rec from an 1981 xs 650 I wired it all up according to the above diagram and still no charge. So I began the diagnostic tests and in the process found that when I disconnected the green from the reg/rec and hooked it directly to my (-) terminal on my battery and I got 14.4 VDC, Which to the best of my knowledge means two things either bad ground to the reg/rec or bad regulator. So here are my questions…
1. Is there something in my wiring that could cause my reg/rec to burn up?
2. Why in the original separate reg/rec is the black going to the brushes grounded, and now in the new diagram it is fed “juice”? Leaving the green the “controlled” (-) from the Reg/ rec to the (-) side of the brushes this being the “green wire to the brush assembly”
Do we switch the roles of the brushes when using these earlier models Reg/rec?
Thanks everyone for this great site. Been lookin for a couple years & finally just got a ’79. I picked up a reg/rec from eBay. It’s actually off an XJ550. I took a good look at it & yup, it’s got 3 white wires, a red, a black, a brown wire and a yellow wire. WTF? YELLOW?!? Should I hook it ip to the green from the stator? I don’t wanna just assume I should. Can anyone or everyone help? I don’t have the dough to be burnin up my charging system.
fire it up without the yellow wire not conected and see if you get a charge, there is a yellow wire coming from the alt witch is not required…….
@pete bailey,
Thanks for the idea, but if I do that, it still leaves the green wire from the stator with nothing to hook up to. Unfortunately I’m not even at the rewiring stage yet. Right now my bare frame is sittin on the garage floor waiting for my G&L hardtail to get here (any day now). I’m just trying to get my crap together about wiring up the charging system. That’s gonna be the hardest part for me. Well, that and the carbs. I’ll be having questions bout those too when I get to em.
the green wire from the stater should connect to green from reg/rec. remember the green wire is normally from the brush………….
Thanks again Pete. But there exactly is my problem. I don’t have a green wire on my reg/rec. It’s yellow. All the other colors are there…red, black, brown & (3)whites, but no green. Yellow instead. That’s why I was wondering if I should hook everything up as in the diagram above, but the yellow from my reg/rec to the green from stator?
Thanks Ted and Wayward Wayne for your diagram and hints! I followed it with only slight mods, and got my bike running quickfast
The tip about switching the orange and gray if you get backfire through the carbs saved me a lot of time troubleshooting! Was able to recognize what was going on and fix it quick. Keep up the great work!
i used the diagram and got the bike to start and run but backfires alot and wont hold a charge. seems like it dies while i ride it any suggestions??
its a 81 with the tci ignition and i was told to unground the stator should i have not done that?
i have a 79xs and im using a reg/rect combo from an 81…the wires coming from my stator are confusing me. i have the 3 whites, but the other two wires are just black…i guess what im asking is which brush goes to which wire on the reg/rect…so looking at the picture, the wire on the left would go to…and the wire on the bottom right would go to … any help?
If anyone is having problems with the wiring go on youtube and search XS650 Charging System How to Wire it Up – Continued . this is what i followed and it was perfect. Its very easy.
dang it!! (does not subscribe to youtube)
why does the orange go from the reg/rec to the +batt? i thought the 3 whites bring ac to it and the orange sends pwr out??
in the video it is called brown and goes from the regrec to key sw and brush,, in the diagram,, brown or orange goes from regrec to brush and batt+???
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?
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
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) http://bit.ly/AtkohI
ok thx , ill do that