Replacement RR and wiring plug to it

I took my bike apart tonight and did the Electrosport flowchart to find out where my problem is. I got intermittent readings with the bike running and checking the voltage return. Sometimes it was above 13.5 and then the next time it was in the 11s. I traced the chart to check the wiring to the RR and found the red wire to the RR was brittle and about half the tiny wires that are spun were broken. This would seem to explain the irregular readings. I am going to replace the RR as it appears to be the original and doesn't have any cooling fins.

I also need to replace the plug that goes into the side of the RR. First I can't seem to get it out of the RR. Is there a trick or is it just melted together? Second, where can I get a plug with the wiring tail attached so I can splice in a new plug? Thanks in advance for any help!

 

eleman:

There should be a little tab on your RR plug that needs pushed in, using a screw driver, and with the tab pushed you pull the wiring plug out. Mine came out pretty hard too!

You can get a new blank plug from the Dennis Kirk cataloge. Go to the electrical section were the RR's and stators are and you will see it on the bottom of the page. Now it does not say it fits the VFR's but it does! The 1990 to 1997 versions. The catalogue says PC800, CBR 900's? and something else. The PC800 one is what I bought. You need to cut the old plug housing off, the you have to solder new brass tabs on and install them in the new plug housing.

I'll tell you what, PM me and I'll get you the part number and go into more depth with you then.

BZ

 

Eleman,

I think it was you who posted a similar question over on VFRD. I make a custom harness for the R/R that beefs up the wires significantly, and I can provide that for you, or just the plug like the Dennis Kirk catalog has. Let me know if you need it.

 

Tightwad,
Did you get the pics to put the harness together for the 4th gen? I am interested if you have it finished. I am not exactly the most mechanically inclined person but I can get things figured out. From what I have read, this is going to be necessary and a plug and play fix is perfect. Let me know how to go about purchasing your harness. Thanks, eleman

 

eleman,

I am not 100% certain my plug fits, it doesn't have the blank spot in the bottom middle. That shouldn't matter really though.

My harnesses currently fit 2000+ models. As soon as I get the time to make one for the 1990-1999 models I will be doing so(possibly next week). 3rd and 4th gen(up to 1999) should be the same, as long as that plug fits.

I will post a picture when I have made one, as well as dimensions. If you are in a hurry, PM me on the VFRD forum and I will try to rush one for you.

Tightwad

 

tightwad

i need one for my 95 vfr 750...how soon could you make one and ship it?
i also pm'ed you. thanks anthony

 

Done and working great

I forgot to post that I got my bike all back together and it works great. The Electrosport flowchart was awesome!

And Bubba, thanks for the tip on Dennis Kirk. I was totally bumming because I couldn't find that plug anywhere. Then I saw your post, got online and ordered 2. It was perfect. I even told Tightwad about the plug in order to help the process of building the 4th gen harnesses.

Thanks again to all who helped, including EVL_TWN who lives nearby and helped on the phone.

 

Does anyone / or can anyone provide a step-by-step on bypassing the wiring harness for the R/R?
I have a similar problem and my wires and plug for the R/R are FRIED!!!
I need all the previously mentioned...Not afraid to Do it myself...
Just not sure on some of the specifics for the bypass procedure.

Any info would be appreciated!
Thanks

 

No problem!

BZ