Regulator Rectifier Wiring

[sikatri]

Hi all. I need to do some minor arranging of components and I want to add some wire about 6” to my regulator rectifier wiring on my 2005 Triumph Thruxton. Anyone have an idea what gauge the wiring would be? None of the manuals I have contain wire gauges which to me seems a bit odd. I was planning on cutting the cable staggered to keep wiring in order and add a segment of wire soldered connection with heat wrap around the connections and a large over the whole cable. Thoughts appreciated. As the regulator rectifier sits in the new location the connector barely reaches the headlight housing where it usually is located.

The red yellow wiring on the left of the brake lever is where the regulator rectifier is now located and the white connector is about as far as it will reach the headlight housing.

And this is where the regulator rectifier is located.

 

[sikatri]

Further investigation the three yellows are 16AWG and the black and red are 12AWG. I’ll have to go see if I can find some in the right colors or at least the right AWG at local auto stores. If not I’ll order. Some places might sell by the foot. I don’t need full spools.

And apart, now to shop when I go out later today.

 

[sikatri]

Progress, found the right AWG!

I’ll see about making the harness extension tomorrow.

 

[sikatri]

Had to order the locking spade connectors. Tried cleaning the old and said f’ this! LoL.

 

[sikatri]

Decided to make my life a bit easier. Going to give these a try.

Never tried something like this. New to me.

 

[sikatri]

Hopefully will have the locking spade connectors by tomorrow.

 

[sikatri]

Worked great!

I’ll cover the new length with shrink wrap. I’ll leave this alone until I get the spade connectors.

 

[Rocky]

Nice neat work

 

[sikatri]

Nice neat work

Never knew about these before. The outer color ring melts and creates a watertight seal as the wrap shrinks and the solder liquifies.

 

[Greyfell]

Decided to make my life a bit easier. Going to give these a try.
View attachment 53524
View attachment 53525
Never tried something like this. New to me.

I haven't personally used those, but have seen them in use. They do the job, and are easy to use.

If you have a heat gun, with a "curl-back" fin on the front, that will speed up the process evenly melting the solder around the tube.

 

[sikatri]

My spade connectors arrived! Now back to the garage!

And a few misc other electrical mods.

 

[sikatri]

Rectifier regulator fixed. Everything tested and hooked up. Appears to all work.

 

[sikatri]

Good thing is I now have plenty of these spade connectors! Might order some of the female ones if I need to repair something else. The plastic housings are easy enough to save, but might look into seeing who sells those as well. Interestingly all the connectors in the light housing were different. Makes assembling easier.

 

[Qship]

Looks great. Nice and tidy, well done.

 

[solomon]

Never knew about these before. The outer color ring melts and creates a watertight seal as the wrap shrinks and the solder liquifies.

Seems good! Nice and neat. I might have to get some and stop the usual bodge-connections. To quote a great American architect, God is in the details. I've never forgotten that quote after being given a dressing down on a student project, being told that.

Why doesn't the heat great enough to melt the solder melt the plastic sleeve?

 

[sikatri]

Seems good! Nice and neat. I might have to get some and stop the usual bodge-connections. To quote a great American architect, God is in the details. I've never forgotten that quote after being given a dressing down on a student project, being told that.

Why doesn't the heat great enough to melt the solder melt the plastic sleeve?

Solders melting point is likely lower. Prolonged exposure it probably would. It’s rather quick. Are you an architect by chance?

 

[solomon]

Solders melting point is likely lower. Prolonged exposure it probably would. It’s rather quick. Are you an architect by chance?

I was a long time ago. That probably explains why most of my motorcycle mechanics involve sitting and thinking. Then reappraising and rethinking.

Anyway, I've just saved some of those solder seal connectors in my eBay watch-list. They look like a box of sweets! Once I've given it more thought, I'll order them.

Actually, you're a life saver. My project-bike engine is what's left from a fire; the alternator wires outside the crankcase melted away. I've literally been thinking for two years how best to make the three internal connections, feeding new wires out of the case. Need to be strong, reliable, oil proof.

 

[sikatri]

I was a long time ago. That probably explains why most of my motorcycle mechanics involve sitting and thinking. Then reappraising and rethinking.

Anyway, I've just saved some of those solder seal connectors in my eBay watch-list. They look like a box of sweets! Once I've given it more thought, I'll order them.

Actually, you're a life saver. My project-bike engine is what's left from a fire; the alternator wires outside the crankcase melted away. I've literally been thinking for two years how best to make the three internal connections, feeding new wires out of the case. Need to be strong, reliable, oil proof.

I’m an architect as well, sort of semi-retired at this point. Getting on in years. LoL. I’ve never used them before, but technique and technology changes. Seemed like a good solution. I was also a mechanic while studying at the university here, so I’ve seen changes. LoL.