Do you have to get the wire harness for the 07 as well? It doesn't look like a plug and play mod. Just curious about this, because my hids seem to draw a bunch of power, and I would like to put less stress on the system.
Why would you do this mod...?
This is a mod that I have done before on a 2001 SV650 and it can be applied to pretty much any bike out there. You can view the thread I made on converting that bike here - http://www.svrider.com/forum/showthread.php?t=111850
I can't take credit for the idea or design except for doing it on my FZ1. The real credit goes to DEcosse, who isn't a forum member here but is on several other bike related sites and has done this mod to all his bikes of varying makes and models. You can read more about it and some of the theory behind it here - http://eviltwinsbk.com/forumz/index.php?topic=276.0
This mod completely eliminates the white connector and related wiring and replaces the stock regulator/rectifier with a much better MOSFET unit. All new weather tight connectors are being used too. In my particular case, I am also relocating the RR to the empty area where the stock air box was since I have pod filters. This will also shorten and compact the RR part of the charging system, causing even less resistance and points of possible failure.
Here is the basic wiring diagram of what I did. Again, credit goes to DEcosse, the author of the thread I linked above from eviltwinsbk forums. While the diagram shows the black and red wires coming out the the stock RR separately, on the FZ they come out all together and go to the white connector, separating later in the wiring harness. The FZ still has the intermediate harness that is to be eliminated.
Answers to a couple questions that I know will come up regarding the new wiring.
1. What's the point of running new wires from the battery?
Direct wiring to the battery from the RR output gives more consistent charging of the battery since there are less points of failure (multiple factory connections in the stock harness) and the wires being used for this are larger 12ga wires. The stock wiring from the RR connector is small gauge and also is not ideally routed/coupled - it actually splices into the wire harness with a crimp coupler that has been known to oxidize & fail. Many are under misapprehension that the R/R ONLY carries the current required to keep the battery charged - it actually carries ALL the current that the bike consumes PLUS the charging current for the battery.
So a 12ga wire directly coupled to the battery ensures there is minimal voltage drop across that larger grade wire than OEM wiring. Performance is thus improved in power delivery to the bike's system as well as the charging voltage applied to the battery.
2. Why the additional fuse? Why not wire it into the existing fuse box?
It provides a measure of safety if there is a short in the system. Running the wires into the factory fuse box would actually be more work in my opinion and not be as simple because of trying to install the wiring into the fuse box. The external fuse holder is easy to install and keeps the charging system wiring separate for ease of troubleshooting if there are issues later.
On to the parts I am using!
The replacement RR I am using is a FH012AA. This is commonly found on 07+ R1s, some VStar bikes and newer FJRs. It's rated at 50A where the stock SH650C-11 RR is only rated at 18A. The Yamaha part # for the FH012AA RR is 1D7-81960-00-00 and it runs for about $131 new according to ronayers.com. I picked mine up on ebay for $90 shipped.
The new connectors that I am using are all sourced from easternbeaver.com. These are "build yourself" connectors, meaning that you need to install the wires into them but they are otherwise ready to go. The RR connectors are identical to the OEM ones and are far superior to anything else on the bike.
An inline 30A fuse is also being added to the system as an additional safety precaution and is also sourced from easternbeaver.com and is weather tight too.
Other items needed are 12ga wire in black and red, 30A ATM fuses (the small ones like the other fuses in the bike), ring connectors for 12ga wire to attach to the battery and shrink tube.
~1 FH012AA Regulator/Rectifier - new or search ebay for 07+ R1, 06+ FJR or 07+ VStar XVS1300. Yamah part # 1D7-81960-00-00
~1 set of Furukawa plugs for the FH012AA RR, get them from here - http://easternbeaver.com/Main/Elec__...onnectors.html
~1 Metri-pack 280 ATM fuse holder for 12ga
wire from here, order the "MP280 Fuseholder (14-12 AWG)" and specify 12ga
in the notes when you pay - http://easternbeaver.com/Main/Elec__...seholders.html
~1 pack of 12ga
wire in RED
- AutoZone or similar
~1 pack of 12ga
wire in BLACK
- AutoZone or similar
~1 pack of 14ga
wire in WHITE
to extend the stator wires - AutoZone or similar
~1 pack of Ring terminals for 12ga
wire - AutoZone or similar, look for "Weatherproof" if available.
~Heat shrink tube.
~30A ATM blade fuses, these are the small ones - AutoZone or similar