HOWTO: R6 Voltage Regulator conversion

Moderators: Site Director, FZR Forum Moderators

User avatar
tommyj27
Level 9.5
Level 9.5
Posts: 970
Joined: Wed May 07, 2008 10:59 am
Location: Minneapolis, MN

HOWTO: R6 Voltage Regulator conversion

Postby tommyj27 » Sat Jun 21, 2008 1:59 pm

Image

My VR swap Howto has been moved to the Wiki! Click here to access that internet tube.

Please continue to use this thread for comments/questions on the mod. Big thanks to Shogun for getting everything on the wiki for us!

User avatar
billy_awesome
Level 2.0
Level 2.0
Posts: 215
Joined: Fri May 09, 2008 9:49 am
Location: London On.
Contact:

Re: HOWTO: R6 Voltage Regulator conversion *IN PROGRESS*

Postby billy_awesome » Sat Jun 21, 2008 2:40 pm

I can help you if you need more info, I just did the r6 VR swap a few weeks ago.

naelas has a great write up on it already though......http://naes.afraid.org


maybe we can grab some info from his website, I can ask for his permission I know him threw msn LOL

User avatar
tommyj27
Level 9.5
Level 9.5
Posts: 970
Joined: Wed May 07, 2008 10:59 am
Location: Minneapolis, MN

Re: HOWTO: R6 Voltage Regulator conversion *IN PROGRESS*

Postby tommyj27 » Sat Jun 21, 2008 2:51 pm

I know that naeslas has a great one, Geo has good info too, along with the stuff from the archives. I'm writing this up as a "How I did it" article, since I did mine slightly differently; I was going to link to all the other ones I know of as well. One thing that would be really nice to have from Naeslas is permission to use his spiffy troubleshooting chart locally, rather than linking to it all the time.

User avatar
tommyj27
Level 9.5
Level 9.5
Posts: 970
Joined: Wed May 07, 2008 10:59 am
Location: Minneapolis, MN

Re: HOWTO: R6 Voltage Regulator conversion

Postby tommyj27 » Sat Jun 21, 2008 5:42 pm

all done, anything I forgot?

User avatar
haunter
2000+ Posts
2000+ Posts
Posts: 2266
Joined: Fri May 09, 2008 9:17 am
Location: Urbana, Il USA
Contact:

Re: HOWTO: R6 Voltage Regulator conversion

Postby haunter » Sat Jun 21, 2008 7:50 pm

looks good


FYI I had 2 plates made today(cam was outta batteries) for my R6 VR....one that sits in the hole you put foil in

and one that goes behind it and sits flush with the rest of the vr, put thermal paste in there too.....between the plates and the VR.

my buddy water jet'd them outta 6061 and I'm sure for a pretty cheap price he would do more sets of em

User avatar
megaloxana
2000+ Posts
2000+ Posts
Posts: 2282
Joined: Thu May 15, 2008 5:05 pm
Location: Hanover, PA 17331
Contact:

Re: HOWTO: R6 Voltage Regulator conversion

Postby megaloxana » Sat Jun 21, 2008 8:02 pm

haunter wrote:looks good


FYI I had 2 plates made today(cam was outta batteries) for my R6 VR....one that sits in the hole you put foil in

and one that goes behind it and sits flush with the rest of the vr, put thermal paste in there too.....between the plates and the VR.

my buddy water jet'd them outta 6061 and I'm sure for a pretty cheap price he would do more sets of em

You got any pictures of those plates, haunter? I fried an R6 regulator recently and really need to do something about it. I'd be willing to buy a set.

tommy- great write-up and very clean install.
'92 FZR 600
Airtech R1 kit \*/ 520 conversion \*/ 14F-47R gearing
K&N pod filters \*/ Stage 3 jet kit \*/ Factory Pro shift kit \*/ Full V&H SS exhaust
Custom '02 R6 undertail \*/ YZF gas tank \*/ Raised via dogbones \*/ custom flush turnsignals
Full R6 brake set-up \*/ SS lines \*/ Progressive fork springs \*/ ZX2 coilpack


ADD YOURSELF TO THE OFFICIAL FZRONLINE GOOGLE EARTH MAP :bunny :banjoman

User avatar
tommyj27
Level 9.5
Level 9.5
Posts: 970
Joined: Wed May 07, 2008 10:59 am
Location: Minneapolis, MN

Re: HOWTO: R6 Voltage Regulator conversion

Postby tommyj27 » Sun Jun 22, 2008 10:01 am

haunter wrote:looks good


FYI I had 2 plates made today(cam was outta batteries) for my R6 VR....one that sits in the hole you put foil in

and one that goes behind it and sits flush with the rest of the vr, put thermal paste in there too.....between the plates and the VR.

my buddy water jet'd them outta 6061 and I'm sure for a pretty cheap price he would do more sets of em

I would definitely be interested in the smaller plate and probably the mounting plate as well. Get some batteries for that camera!

User avatar
yamaha_george
5000+ Posts
5000+ Posts
Posts: 5853
Joined: Fri May 09, 2008 8:46 am
Location: west london UK
Contact:

Re: HOWTO: R6 Voltage Regulator conversion

Postby yamaha_george » Sun Jun 22, 2008 10:31 am

tommyj27 wrote:Ok, we may not need another Howto replace your Voltage Regulator


TJ,
Nicely done Mate :tks: ClapHands

The only downside is You used those NAFF hard plastic covered connectors which in my experience are too rigid for a bike. They crack & break at the crimp point even with their own manufacturers tool ( or any other I have tried )


I did give the part numbers of The RS component versions and they are available in the states via internet.

bweight
Level 4.0
Level 4.0
Posts: 421
Joined: Wed May 07, 2008 4:03 pm
Location: Sudbury, ON, Canada
Contact:

Re: HOWTO: R6 Voltage Regulator conversion

Postby bweight » Sun Jun 22, 2008 10:35 am

Think I'm gonna have to test my 400 VR.. I noticed yesterday when I was finishing up on it, that it seems the lights dimmed/brightened at certain times.. Course, it might be a loose ground somewhere, but I suppose it doesn't hurt to check the VR..

Great write up though.. definitely something to look at when replacing these problematic items..
89 FZR 400
Custom Paintjob
600 plastics.
06 - R6 Shock
FZR600 Motor
Polished Frame & Engine Covers

Soon to be:
Broke........

Image
FZROnline.com Decals. Get yours Now!!!

User avatar
Lasse
50+ Posts
50+ Posts
Posts: 72
Joined: Sat May 17, 2008 6:17 pm
Location: SWEDEN

How did YAMAHA do it ?

Postby Lasse » Mon Jun 23, 2008 11:28 am

Hello !

I want to know how YAMAHA them selves did do it ( on the FZR-600 , 1989 - 1999 ) when they went with the 5 lead VR insted of the 4 lead VR ?

OLD style VR , 4 lead ( 1989 <-- 1994 ) Yamaha part # : 47X - 81960 -A2 - 00
NEW style VR , 5 lead ( 1995 --> 1999 ) Yamaha part # : 4JH - 81960 - 00 - 00

Please can anyone post a wireing digrams of a 1995 - 1999 ?

Please can anyone post a wireing diagram of a 1989 - 1994 ?

..just to compare how YAMAHA did it !


:worthlesswithoutpics:

.
// Lasse from SWEDEN.

Yamaha FZR-600 ( 1990 )

User avatar
tommyj27
Level 9.5
Level 9.5
Posts: 970
Joined: Wed May 07, 2008 10:59 am
Location: Minneapolis, MN

Re: HOWTO: R6 Voltage Regulator conversion

Postby tommyj27 » Mon Jun 23, 2008 9:25 pm

The old VR did not have a ground in the plug because the casing of the part was grounded, hence the ground wire on the bolt in the first photo. The plug contains the three white AC wires and the Red positive wire.
Image
The new style VR has the ground in the plug, which is why there is an extra pin
Image

User avatar
yamaha_george
5000+ Posts
5000+ Posts
Posts: 5853
Joined: Fri May 09, 2008 8:46 am
Location: west london UK
Contact:

Re: How did YAMAHA do it ?

Postby yamaha_george » Tue Jun 24, 2008 8:13 am

Lasse wrote:Hello !

I want to know how YAMAHA them selves did do it ( on the FZR-600 , 1989 - 1999 ) when they went with the 5 lead VR insted of the 4 lead VR ?

OLD style VR , 4 lead ( 1989 <-- 1994 ) Yamaha part # : 47X - 81960 -A2 - 00
NEW style VR , 5 lead ( 1995 --> 1999 ) Yamaha part # : 4JH - 81960 - 00 - 00

Please can anyone post a wireing digrams of a 1995 - 1999 ?

Please can anyone post a wireing diagram of a 1989 - 1994 ?

..just to compare how YAMAHA did it !


:worthlesswithoutpics:

.



Hi,
If you look at pic No.1 (the old set up you will see that the ground wire (the 5th wire ) has a ring connector on it.

The newer model is identical in the harness EXCEPT it goes in the plug. The case is grounded thro the frame mounting.

HOWEVER old bike hands "know" that such frame grounds are prone to painting over by the PO & corrosion. So we add a wire as well just to be sure we do have a " proper " ground when we do the mod from 4 to 5 wire VR's

see:- pictures 2 & 3of:-

http://www.saltmine.org.uk/fzr/vr.html

TheRose
Site Newbie
Posts: 33
Joined: Thu Aug 14, 2008 7:56 pm

Re: HOWTO: R6 Voltage Regulator conversion

Postby TheRose » Sun Aug 17, 2008 10:58 pm

Thanks tommyj27 for an awesome writeup...one mistake I made while following this was I bought the wrong connectors...Radio Shack sold the following as "insulated disconnects":
Image

which are basically the normal disconnects wrapped in a hard plastic...the problem is, because of this plastic the connectors wont all fit in the new VR. I'm going to go back tomorrow and get the ones that look like your picture (which is what I should have done in the first place) but just in case anyone else is thinking of making the mistake I did, just say no...
Image

User avatar
tommyj27
Level 9.5
Level 9.5
Posts: 970
Joined: Wed May 07, 2008 10:59 am
Location: Minneapolis, MN

Re: HOWTO: R6 Voltage Regulator conversion

Postby tommyj27 » Mon Aug 18, 2008 8:11 am

Yeah, I looked at those and almost bought them too, then I thought about how i was going to fit all that plastic into that connector space. Maybe with some sand paper to sand down the plastic a bit they might fit.

User avatar
yamaha_george
5000+ Posts
5000+ Posts
Posts: 5853
Joined: Fri May 09, 2008 8:46 am
Location: west london UK
Contact:

Re: HOWTO: R6 Voltage Regulator conversion

Postby yamaha_george » Mon Aug 18, 2008 12:13 pm

tommyj27 wrote:Yeah, I looked at those and almost bought them too, then I thought about how i was going to fit all that plastic into that connector space. Maybe with some sand paper to sand down the plastic a bit they might fit.


Guys,
In another VR thread I did give the proper part numbers for the RS Components spade connectors with silicon rubber sheaths. Here they are again (& they are available thro the internet http://www.rs-components.com/index.html)

6.3mm spade terminals (male)....Pt/No. 488-1279
6.3mm recepticals (female)........ Pt/No. 488-1235
Receptical covers .........................Pt/No. 488-1314
spade covers................................Pt/No 488-1320

These are soft flexible covered terminals that can be silicon glue injected to really keep out water for dirt bikes (even power washers) or just use conductive grease in them or use as is which has been fine for everyday wear & tear in the UK.


Return to “WIKI - Discussion, Submissions, Corrections...”

Who is online

Users browsing this forum: No registered users and 1 guest