Charging system upgrade

[Biker9090]

I'm in the middle of upgrading my CBF500 charging system to that of a Blackbird (has been done a few times before).

The issue us that the new stator has MUCH thicker wires than the original.

First question is it is better to crimp on new connectors to the old wiring harness (chopping off the old stator plug) so it can connect to the new stator or should it be directly soldered?

Secondly, I'm considering changing the reg/rec but upgraded ones have slightly different plugs/connectors. OEM has 3 to the stator, one to the main fuse and another to what looks like an earth circuit to the rear light. Aftermarket has 3 to the stator, one (I'm assuming) earth or negative and one fused live direct to the battery.

[Krikkit]

Biker9090 said:

First question is it is better to crimp on new connectors to the old wiring harness (chopping off the old stator plug) so it can connect to the new stator or should it be directly soldered?

Crimp vs solder is a question that will be argued long after we're dead; done correctly both are perfectly fine. FWIW I would match what the bike's original system has.

Biker9090 said:

Secondly, I'm considering changing the reg/rec but upgraded ones have slightly different plugs/connectors. OEM has 3 to the stator, one to the main fuse and another to what looks like an earth circuit to the rear light. Aftermarket has 3 to the stator, one (I'm assuming) earth or negative and one fused live direct to the battery.

Sounds fine either way - if you get a clean earth then it won't make any real difference

[KTMsm]

The best way is a single butt slice crimp connector deleting the old plug

The problem with this is you would have to cut it to remove it in the future - I've done this on many bikes that have had troublesome / melted connectors. I don't see it as an issue

Regarding updating the rectifier, essentially they are the same: 3 wires, positive and negative

[anonymous-user]

Have a read around this site - the guy has done tons of testing

http://www.roadstercycle.com/#SH847_SERIES_RR_KITS...

I've wired mine directly to the battery.

[gareth_r]

These heatshrink solder connectors (other sources are available) make splicing easy

https://www.autoelectricsupplies.co.uk/p/heat-shri...

If possible, stagger the joints so that there isn't a big lump in the harness.

Edited by gareth_r on Tuesday 26th December 16:25