SV650 - Dreaded Reg / Rec + Removing old Crash bung mounts?

Hi Folks, first proper post here aside from a few PMs back and forth, but hopefully have two easy ones for you!

Couple months back, picked up my first SV as a big bike after Uni, having sold my Thundercat to fund my studies there. The SV faithfully got me to interviews on time, landed me a job, before the reg/rec promptly went Pop. She's since been sat for a couple months over winter, and now things are settled I have time to tinker.

First thing, snagged a replacement reg/rec off ebay, hoping it'd just be a plug-in job - however terminals look completely different. Should have known, given the mess of wiring on the original:

http://imgur.com/EIWs4oF

The replacement is as below - I'm presuming there's going to be some cutting going on and "blades" added, unless there's a readily available terminal block? Top two wires are straightforwards enough, is there any set order for the bottom three yellow ones however?

http://imgur.com/OCfGEWf , http://imgur.com/gQtnuEG


Last but not least, the PO has had crash bungs fitted at some point - the bung is no longer there, just the mounting hardware. Bolt looks somewhat substantial however, so don't want to take them both off and have the engine drop out! For the moment I want them off, so what size bolt would I need to revert it to stock?

http://imgur.com/7skjBVG

Many thanks!

[21QUEST]

Someone has changed the connector blocks on the loom side as well...should be two connector blocks for the 99-01 curvy. The 02 curvy has a single connector block.
The new rectifier has the correct number/type for the 99 Curvy..

The yellow wires on the rectifier can each connect to any of the yellow wires on the loom side.

The connector blocks I believe are readily available but if you are not in a mighty rush, I probably have a loom that could be raided to provide the connector blocks you need...I would know by tomorrow evening. You can then have them for the cost of postage.

Re the last pic, looks the crash bung replaced the original bolt completely as opposed to utilising the original bolt.
I have to have a look at mine tomorrow...also, as something doesn't look quite right(no, not the dirt ) in that pic...could all be in my head though .

In any case, the engine won't suddenly drop out but you wouldn't want to ride it without replacement bolts either.

edit: You did all relevant checks to confirm it was indeed the rectifier at fault?

[squirrel_hunter]

Originally Posted by 21QUEST

Re the last pic, looks the crash bung replaced the original bolt completely as opposed to utilising the original bolt.
I have to have a look at mine tomorrow...also, as something doesn't look quite right(no, not the dirt ) in that pic...could all be in my head though .

Nope I agree with you there. I've checked a couple of my pics and it looks like you are missing a frame plate. Its a black flat triangular plate that the front mount bolt goes through, the plate is connected to the inside of the frame around about where the weld is.

I would say that the crash bung has replaced this. I would also wonder if you are missing the engine spacer. So if you want the bung and mount out it looks like you will need the mounting plate, bolt, and spacer.

Whats the other side like?

The lad I bought the bike off made mention that the loom may have been changed at some point, so that may well explain the connector block / blocks change, as well as why the old reg blocks had been hacked about.

Cheers for the reply re both blocks and cabling - if I can get a nod towards part numbers or where to look (Halfrauds, maplin?) I'll try to pick some up locally first, both to save yourself the faff of taking looms apart and as I've only got the next couple of days to play with the bike before being snowed under back at work.

Won't be riding it anywhere with bolts out - it's either looking at replacement bolts or replacement blank bobbins. Either'll do! Will wait 'till you get back to me tomorrow on that one.

Also, def. the reg - bubble of molten solder pushing out the rubber bung where the cables meet was a bit of a giveaway!

Originally Posted by squirrel_hunter

Nope I agree with you there. I've checked a couple of my pics and it looks like you are missing a frame plate. Its a black flat triangular plate that the front mount bolt goes through, the plate is connected to the inside of the frame around about where the weld is.

I would say that the crash bung has replaced this. I would also wonder if you are missing the engine spacer. So if you want the bung and mount out it looks like you will need the mounting plate, bolt, and spacer.

Whats the other side like?

Other side is identical from what I remember, no plates on either side, though something of a spacer on the engine itself behind. Will take a look at snapping a couple pics from a different angle

Edit, pics as follows: http://imgur.com/Njow9xg , http://imgur.com/hR5GQ2H

Only seperate piece is the bung mounting, the fatter section that ends just where the frame begins - looks as if I may get away with just a bolt~?

[squirrel_hunter]

It looks like the connector block was changed to incorporate both plugs in one. I wonder if its not the first time the reg rec has failed on that bike. As for where to get a replacement pair of connectors, I doubt Halfords will have what you need, Maplins may. Suzuki I don't think do these as part numbers, they'll sale you a new loom however but you can find them from specialist suppliers, doubt it will be anything off the shelf though.

Those pictures of the crash bungs are better, looks like the pate and the spacers are there so just looks like its the bolts you need.

Originally Posted by squirrel_hunter

It looks like the connector block was changed to incorporate both plugs in one. I wonder if its not the first time the reg rec has failed on that bike. As for where to get a replacement pair of connectors, I doubt Halfords will have what you need, Maplins may. Suzuki I don't think do these as part numbers, they'll sale you a new loom however but you can find them from specialist suppliers, doubt it will be anything off the shelf though.

Those pictures of the crash bungs are better, looks like the pate and the spacers are there so just looks like its the bolts you need.

Had a look at the microfiche for the connector blocks there - as you say they seem to be incorporated into the loom itself. Bugger! May look at a patch job in the very short term before sorting out the proper blocks.

I've also been eyeing the microfiche to find part numbers, and by extension sizes for the bolts I'll need, but can't make head nor tail of them! Nothing on the frame side of things ( http://www.robinsonsfoundry.co.uk/co...v650xframe.htm ) so looked at Cyl head (http://www.robinsonsfoundry.co.uk/co...lheadfront.htm) - would I be right in thinking I'm looking for bolts number 26 + 27, part #01550-10807 ?

[andrewsmith]

Originally Posted by squirrel_hunter

It looks like the connector block was changed to incorporate both plugs in one. I wonder if its not the first time the reg rec has failed on that bike. As for where to get a replacement pair of connectors, I doubt Halfords will have what you need, Maplins may. Suzuki I don't think do these as part numbers, they'll sale you a new loom however but you can find them from specialist suppliers, doubt it will be anything off the shelf though.

Those pictures of the crash bungs are better, looks like the pate and the spacers are there so just looks like its the bolts you need.

I would say so.
It looks like its had a pattern R/R installed from Ebay or M&P. For the connectors these do some of the japanese spec connectors as I've had to change the 12v side on mine http://kojaycat.co.uk/

Edit: This is the OEM 12v connector http://kojaycat.co.uk/epages/9500004...Products/US3WW
And this is the 3 phase side http://kojaycat.co.uk/epages/9500004...Products/US3WB

[squirrel_hunter]

The 12v connector is 2 wires so you will need this one not a 3 wire. Can never remember the name of that site, thanks.

As for the bolts yes that's them part #01550-10807. Off the top of my head it a 14mm socket and will be a little on the tight side...

[21QUEST]

Hi bud, I've got the connectors and bolts you need. You can have them for the cost of postage.
I'd leave the some length of wiring on connector block, so all you have to do is a bit of soldering and some shrink and you'd be done. I'd even add some heat shrink tubing if you like...as I bought metre lengths of various sizes a while ago so no biggie to do that.

PM me your address and I should be able to send them off tomorrow and then I'd let you know how much it cost to send.

By the way, I'm not sure(without having a look) where the Diode(believe that's what it is) is, on the K2 loom on your bike....up to K1 it's next to/taped to the rectifier connector blocks.
I'm only mentioning it as I can't make it out in the images you posted.