SuzukiSavage.com - oh the joys - replacing the rectifier 1100

Pine

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oh the joys - replacing the rectifier 1100
03/03/14 at 07:50:06

Yeah I suspected the rectifier was going bad,

Buy a new voltmeter.. mine died year ago
blew the fuse on the new one, when I forgot to set it properly after testing the internal battery.
Buy fuses
test MC battery .. marginal 12.5 volts
Drop the exhaust... wait go buy a LOONG hex wrench
Test the rectifier .. 18v
To remove the unit
remove battery.
remove all bolts to the battery box
remove unit
Go to the bike shop new unit is $120, to be shipped in next week

This is going to be a royal pain to put back!!!

Angry

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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12673 Fayetteville, NC Gender:	Re: oh the joys - replacing the rectifier 1100 Reply #1 - 03/03/14 at 11:29:58 Pine, you didn't ask first before you spent $120 of your hard earned money. Might there be a trick or two about regulator/rectifiers on the site? Yup, there might be .... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1221083699/0#0
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arteacher Serious Thumper Offline Ride as if your naked and invisable! Posts: 2581 London ontario Gender:	Re: oh the joys - replacing the rectifier 1100 Reply #2 - 03/03/14 at 14:02:39 Why not just replace the diodes in the rectifier? You could even put heavier ones in.
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Re: oh the joys - replacing the rectifier 1100
Reply #3 - 03/03/14 at 14:33:19

There's quite a bit of work involved, these are well potted and digging out the resin may destroy the circuit board.

Somewhere, I recall someone explaining operation and repair or how to build your own.

It's a 3 phase a/c. so you need 6 high power diodes and Zenners. which regulate the up to 100v to 14 by shorting the surplus to ground.
Not terribly efficient if you're trying to wring every watt outta it.

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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12673 Fayetteville, NC Gender:	Re: oh the joys - replacing the rectifier 1100 Reply #4 - 03/03/14 at 17:18:20 This is why they recommend using a 7 wire unit from a bigger Suzuki motorcycle. It is more robust and can dissipate more heat easier. Savage r&r units crap out too easily. Cost way too much too. $120 is highway robbery.
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: oh the joys - replacing the rectifier 1100 Reply #5 - 03/05/14 at 20:44:18 So it's a direct swap (provided you splice 2 power wires together and 2 ground wires together)? ....and much more durable?
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Re: oh the joys - replacing the rectifier 1100
Reply #6 - 03/06/14 at 03:05:08

So they say. I've only done it once and it works fine.

I think the 7 wire units are functionally two rectifier bridges, so you are using them in parallel so each dissipates half the load. Physically, the units are a little bigger but that is OK because they use the stock bolt pattern.

Versy is an electrical engineer so he can give you a better interpretation of what is going on internally with the 7 wire units.

To me, it works, it works better, it can be cheaper to get (wrecked squid bikes are more commonly available) and it should last longer than a stock unit will last because it is thermally stressed less.

Since I was splicing wires anyway to reuse the old connectors, I moved the rectifier up and out into the air flow up by the horn. The units do get warm, so I figured it might help some.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: oh the joys - replacing the rectifier 1100 Reply #7 - 03/06/14 at 07:22:35 Oldfeller--FSO wrote on 03/06/14 at 03:05:08: Versy is an ~~electrical~~ engineer mechanical... know only enough electrical to scare myself.
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Pine

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Re: oh the joys - replacing the rectifier 1100
Reply #8 - 03/06/14 at 07:54:06

This has been a great thread.... I guess I should have made is more plain... this is on the Yamaha Vstar 1100. I had to ride the Savage to the parts store to pay for the Yamaha parts. Nothing wrong with my little 'zuki'. 7000 miles of worryfree riding so far.

I have it mostly back together, one exhaust bolt is being a pain and acting like it wants to cross thread, so I have a guy coming over to "chase" it. Well, we may have to drop the pipes to give him enough room to do so.

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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12673 Fayetteville, NC Gender:	Re: oh the joys - replacing the rectifier 1100 Reply #9 - 03/06/14 at 14:22:54 Trick still works for Yamahas. I did an XV535 with the same trick.
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