Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums - Reply to Topic
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

Thread: Regulator/Rectifier Relocation Procedure Reply to Thread
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  Topic Review (Newest First)
03-04-2017 05:33 PM
majdsaster 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.
03-04-2017 03:38 PM
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

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03-04-2017 03:03 PM
majdsaster Was it necessary to extend the wire harness or does it reach the new location?
06-16-2015 06:44 PM
trooper Done deal, thanks very much for the tip.
08-05-2014 09:23 PM
vulkan My "Relocation"...did this today.Its not plugged in yet because I am getting the die-electric grease.
11-01-2013 12:34 PM
L2fish I like this one much better. More professional and looks like it belongs there.
10-19-2013 10:38 AM

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?
09-21-2013 11:24 AM
Frey Glad i found this Post. I had to replace my R/R this weekend. Cool ideas on relocation.
08-12-2013 01:17 PM
FieroGT42 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.

07-02-2013 11:11 AM
Originally Posted by Goofyfoot2001 View Post
So the rectifier bolts can't be unscrewed? They have to be drilled out? That's kinda whacked from an engineering standpoint, no?
Not always. I unbolted mine. First takes three battery box out of the frame to get to the bolts easier. Then gently unscrew them.

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