GT250 Wiring advice needed.

[gumpt1oo]

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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[ConnerVT]

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.

[jabcb]

+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.

[gumpt1oo]

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!

[jabcb]

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.

[ConnerVT]

That is brilliant information guys! I am struggling to find the Tympanium brand here in the UK,

Here's one