Hi guys, not been around here for a while but have just started to put my GT250 project together and have hit a snag.
I am fitting an after market handlebar switch for the lights, horn indicator etc, and have hit a snag.
On the original switch when the lights switch is turned on the G/W wire and R/G wires from the lighting coils are joined together. I assume this is the compensate for the drain on the battery with the lights on. My problem is the new light switch does not have enough wires to do this.
So my question is if I join the 2 wires together and don't use the lights will it cook the battery/rectifier?
If I leave them disconnected I assume the battery will drain very quickly.
I had thought of fitting a separate rocker switch to turn on the lighting coils when the lights are in use.
Any advice would be much appreciated
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GT250 Wiring advice needed.
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- ConnerVT
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Re: GT250 Wiring advice needed.
I would say all of your assumptions are correct.
Looking at the wiring diagram you posted, there is no voltage regulator on the bike. It uses the battery to behave as the voltage regulator.
As you correctly stated, the stock lighting switch switches in the additional charging coils when the headlight is switched on. The additional load from the lights balances out the additional output from the generator, so the battery doesn't overcharge badly.
Your solution to add an additional switch would work. So would running all the generator coils, and running the lights all the time.
Another solution is to replace the stock regulator with a combination rectifier/regulator. I did this with my T500. Wired the generator coils to be on all the time (eliminating the need to send current to the handlebar switch and back, losing some along the way), and I could then replace the lead acid battery with a more modern AGM battery, as well as upgrade to a higher output halogen headlight.
Looking at the wiring diagram you posted, there is no voltage regulator on the bike. It uses the battery to behave as the voltage regulator.
As you correctly stated, the stock lighting switch switches in the additional charging coils when the headlight is switched on. The additional load from the lights balances out the additional output from the generator, so the battery doesn't overcharge badly.
Your solution to add an additional switch would work. So would running all the generator coils, and running the lights all the time.
Another solution is to replace the stock regulator with a combination rectifier/regulator. I did this with my T500. Wired the generator coils to be on all the time (eliminating the need to send current to the handlebar switch and back, losing some along the way), and I could then replace the lead acid battery with a more modern AGM battery, as well as upgrade to a higher output halogen headlight.
Last edited by ConnerVT on Fri Jul 18, 2014 4:21 am, edited 1 time in total.
- jabcb
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Re: GT250 Wiring advice needed.
+1 on ConnerVT's solution.
I'm using a Tympanium rectifier/regulator & an AGM battery on my GT250.
It costs about $50 on eBay: http://motors.shop.ebay.com/i.html?_nkw ... +regulator
I've wired it up for maximum output (last of the 3 wiring diagrams) as shown here:
viewtopic.php?f=29&t=6786&p=121472&hili ... or#p121472
If you wire the alternator up for maximum output & don't have the light on you will burn out the neutral light & significantly shorten the battery life.
I'm using a Tympanium rectifier/regulator & an AGM battery on my GT250.
It costs about $50 on eBay: http://motors.shop.ebay.com/i.html?_nkw ... +regulator
I've wired it up for maximum output (last of the 3 wiring diagrams) as shown here:
viewtopic.php?f=29&t=6786&p=121472&hili ... or#p121472
If you wire the alternator up for maximum output & don't have the light on you will burn out the neutral light & significantly shorten the battery life.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more
Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
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- On the street
- Posts: 19
- Joined: Mon Sep 17, 2012 6:37 am
- Country: England
- Suzuki 2-Strokes: TS185, TS250, GSX400, GS550, GSXR750, GT250
Re: GT250 Wiring advice needed.
That is brilliant information guys! I am struggling to find the Tympanium brand here in the UK, but can get a Podtronic/Wassell equivalent.
http://www.ebay.co.uk/itm/181023698337? ... 1423.l2649
Thanks again for the info and diagrams, I'm off to the shed!
http://www.ebay.co.uk/itm/181023698337? ... 1423.l2649
Thanks again for the info and diagrams, I'm off to the shed!
- jabcb
- Moto GP
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- Joined: Mon Dec 13, 2010 4:32 pm
- Country: USA
- Suzuki 2-Strokes: 69 T350 thru 75 GT750
- Location: southwestern Pennsylvania
Re: GT250 Wiring advice needed.
I didn't look to see that you aren't in the US.
There are a few other rectifier/regulators that will work fine.
One consideration worth remembering is how you will mount it.
The Tympanium is easy to install under the stock seat.
I don't know about any of the others.
I didn't see the Podtronic dimensions in the link you provided.
Let us know how it works out for you.
There are a few other rectifier/regulators that will work fine.
One consideration worth remembering is how you will mount it.
The Tympanium is easy to install under the stock seat.
I don't know about any of the others.
I didn't see the Podtronic dimensions in the link you provided.
Let us know how it works out for you.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more
Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
- ConnerVT
- Novice racer
- Posts: 963
- Joined: Wed Jan 18, 2012 8:01 pm
- Country: USA
- Suzuki 2-Strokes: T500R (now), T500M (40 yrs ago)
- Location: North of Albany, NY
Re: GT250 Wiring advice needed.
Here's onegumpt1oo wrote:That is brilliant information guys! I am struggling to find the Tympanium brand here in the UK,