Regulator/Rectifier Relocation Procedure - Page 5 - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

LinkBack Thread Tools Display Modes
post #41 of 49 (permalink) Old 08-12-2013, 02:17 PM
I.T. Analyst, Alpha Geek
FieroGT42's Avatar
Join Date: Jul 2013
Location: SE Iowa
Posts: 157
iTrader: (2)
Yes it unbolts. I'm guessing his were rusted solid. I stripped the rust and repainted my battery box with VHT epoxy while I had it out anyway.

Here's my R/R relocation. I just used a flat corner brace designed for 2x4s since it was already on hand. It puts the R/R fins vertical for cooling at idle and barely shows. Wouldn't show at all if I cut it a bit but I was lazy with it. Suspension clears and I cleaned up the wiring with split loom.

FieroGT42 is offline  
Sponsored Links
post #42 of 49 (permalink) Old 09-21-2013, 12:24 PM
Frey's Avatar
Join Date: Dec 2010
Location: Hot Springs AR
Posts: 105
iTrader: (1)
Glad i found this Post. I had to replace my R/R this weekend. Cool ideas on relocation.

Asatru Rede of Honor rule 16:
Honor yourself, have pride in yourself, do your best and forgive yourself when you must.
Frey is offline  
post #43 of 49 (permalink) Old 10-19-2013, 11:38 AM
path's Avatar
Join Date: Sep 2013
Location: Peoria, AZ
Posts: 9
iTrader: (2)
Wink Motivation.

Originally Posted by Puck View Post
Thanks for the info. I did this last week and it worked great! I had previously replaced the rectifier twice and not one mechanic at either shop I went to had the sense to suggest this.
What is their motivation? If you are paying them to treat something, why would they give you the cure?

Shiny side up

1999 Vulcan VN750
1981 Gold Wing GL1100I


path is offline  
post #44 of 49 (permalink) Old 11-01-2013, 01:34 PM
1985 VN-700
L2fish's Avatar
Join Date: Jun 2010
Location: Worcester, MA
Posts: 418
iTrader: (0)
I like this one much better. More professional and looks like it belongs there.
L2fish is offline  
post #45 of 49 (permalink) Old 08-05-2014, 10:23 PM
Senior Member
vulkan's Avatar
Join Date: Jul 2014
Location: North Central Fla
Posts: 450
iTrader: (0)
My "Relocation"...did this today.Its not plugged in yet because I am getting the die-electric grease.

Last edited by vulkan; 09-19-2014 at 04:07 PM.
vulkan is offline  
post #46 of 49 (permalink) Old 06-16-2015, 07:44 PM
Junior Member
Join Date: Mar 2015
Location: near Thunder Bay Ontario Canada
Posts: 2
iTrader: (0)
Done deal, thanks very much for the tip.
trooper is offline  
post #47 of 49 (permalink) Old 03-04-2017, 04:03 PM
Thats 'Mr' Jr Member
majdsaster's Avatar
Join Date: Feb 2016
Location: Key West, FL
Posts: 249
iTrader: (0)
Was it necessary to extend the wire harness or does it reach the new location?

Avatar: George The 3rd
June 2006 - Sept 27, 2013

6th Ride: 2017 Kawasaki Vulcan 900 Custom
5th Ride: 2005 Kawasaki Vulcan 750 (2015 - 2017)
4th Ride: 1981 Kz1000 LTD (2008 - Storage)
3rd Ride: Wife (1999 - 2005)
2nd Ride: 1982 Kz1000 LTD (1983 - 2004)
1st Ride: 1977 Yamaha XS-650 (1981 - 1983)
majdsaster is offline  
post #48 of 49 (permalink) Old 03-04-2017, 04:38 PM
OleDirtyDoc's Avatar
Join Date: May 2011
Location: Norwich,NY
Posts: 15,960
iTrader: (0)
Send a message via Yahoo to OleDirtyDoc
Originally Posted by majdsaster View Post
Was it necessary to extend the wire harness or does it reach the new location?
yes wires should reach

Sent from my LGL34C using Tapatalk

Support your local FREEBIRDS MC
1986/5 Vn700/750 Frankenfook cross eyed bitch "Mellisa Fayhe"

lowered with progessive 412 10" shocks
rejetted for K/N Pods part#rc 2340
sportster seat

'I didn't lose my mind.i gave it away

BRING BACK WOLFIE."Peace and Carrots"RIP
"And I'm a bird"John Lennon Free as a Bird
"I only carry when I have my pants on"Joe Robinson RIP aka Old Dog
OleDirtyDoc is offline  
post #49 of 49 (permalink) Old 03-04-2017, 06:33 PM
Thats 'Mr' Jr Member
majdsaster's Avatar
Join Date: Feb 2016
Location: Key West, FL
Posts: 249
iTrader: (0)
Yes, you're right! I just checked to see how my bracket and clamp will fit and saw the way the wire harness is routed and realized it will easily reach the new location. I should have seen that the first time I looked at it but I'm getting old, (that's my excuse and I'm stickin' with it!)

I don't really have any decent place to work on my bike and looking at it, I don't know how I'd get my hands in there with tools to work on things, then I saw a recycled, OEM R&R online for $29.00 and figured what the hell, for $29.00 I'll get it, mount it and move the plug from the original the the replacement and see what happens.

I Did It! Thanks for your original post Fergy!
(Excuse the length of this but I thought some might find it interesting)

My 2005 Vulcan 750 had left me stranded a couple of times with a weak battery. Everything seemed to indicate the R&R and when I saw Fergy's outstanding method for relocating the R&R and then found a used one online for $29.00, I decided to just get it, mount it and leave the old one where it was.
When I unplugged the wire harness from the original unit it was obvious that there has been a serious heat issue going on. In spite of the nasty appearance of the plug, after I cleaned things up a bit with alcohol and a soft bristle brush, I decided the contacts and wires all seemed ok.

I went to Home Depot and back by the doors and cabinet hardware I got an 8 inch Mending Strap that has predrilled holes for under $3.00

To my surprise, I found the holes were exactly the right spacing to mount the regulator. I drilled two more holes for the U-Bolt and cut off the end of the strap.

After cleaning with alcohol I gave the strap two coats of primer and two coats of black paint.
The environment down here in the Keys is very hard on things, especially if you don't have a garage, I went to West Marine for the hardware so the nuts, bolts, washers and the U-Bolt are marine grade stainless steel, all metric.
I tightened the bolts to serve as mounting studs so I can just put the R&R onto it without having to work with wrenches behind it.

I slipped a piece of 3/8 rubber fuel line onto the U-Bolt, like Fergy did, and then notched the heavy plastic splash guard to fit the U-bolt through so that the threaded ends would be facing out and easier to work on.

The U-Bolt came with a thick steel plate so I cut a piece of fuel hose in half and used the steel piece as a template to squash it flat and drilled holes in the flattened rubber line which I then put on the U-Bolt with the plate over it and then the mounting bracket over the plate. This gave a double thickness of metal where it attached to the frame and also gave a rubber cushion all around

With the bracket in place I placed the R&R onto the studs, added lock washers and cap nuts and tightened them down
After shooting some dielectric grease into the contact holes I plugged the harness into the regulator and used Zip-Ties as a 'Keeper' since the locking tab was gone from the plug.

I live on Big Coppitt Key and to test the bike, I took it for a ride up the Overseas Highway as far as Marathon Key and stopped to have a cup of coffee, figuring that if the bike was still running off the battery without charging it, then it won't have enough juice to start the engine for the ride back. I have a rechargeable power supply which is the equivalent of a motorcycle battery and a set of jumper cables I made with some small clamps and a few feet of 8 gauge wire so I carried these in my backpack, just in case.
SUCCESS!! The battery fired up the bike immediately and I rode back to Big Coppitt. A couple of hours later, a friend from work said we were invited to dinner on the boat of a friend of his at the NAS Marina so we rode to the base on our bikes and once again it started right up and finally, later that evening, it started up with no trouble for the ride home. So the system seems to working and it is charging the battery!
Next payday I think I will plan to take a bike ride up to Key Largo for the weekend and maybe stop along the way to check out some yards sales and maybe even do a little fishing.

Avatar: George The 3rd
June 2006 - Sept 27, 2013

6th Ride: 2017 Kawasaki Vulcan 900 Custom
5th Ride: 2005 Kawasaki Vulcan 750 (2015 - 2017)
4th Ride: 1981 Kz1000 LTD (2008 - Storage)
3rd Ride: Wife (1999 - 2005)
2nd Ride: 1982 Kz1000 LTD (1983 - 2004)
1st Ride: 1977 Yamaha XS-650 (1981 - 1983)

Last edited by majdsaster; 03-16-2017 at 11:22 AM. Reason: To expand this comment with a success story
majdsaster is offline  
Sponsored Links


Quick Reply

Register Now

In order to be able to post messages on the Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

Once registered, your User Name"cannot be changed". We can make exceptions within 7 days, but after that, it is set in stone.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome