Suzuki Boulevard C90 - Wiring Installation (Mod 3)
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- Опубликовано: 26 май 2013
- Video of my installation of Mod-3 conceived by DrJones18LC from the Delphi forums. Had been having some charging issues and believe it to be a stator issue but performed the mod as insurance for the future if nothing else. Possible the issue was in some of the wiring I cut out--hopefully that is the case!
Did the mod today 10-5-16 starting volts at batt 12.4 after mod 13.6. Thanks your vid was great super helpful. Main deal is my bike is back hauling s
What to do with the three stator wires
Sorry I am just seeing these comments. Aaron Frizzell, it really isn't that hard if you take your time and plan out exactly what you're going to do. That's what I hoped people could use this video for! You can always pay somebody to fix it after you screwed it up lol
I wasn't having problems, but voltage was in the low 13s and I went ahead and did this on mine. After the mod I was hitting consistent 14+ volts when cruising, and it seldom drops below 13.7 when running. It's easy to do with a minimum of wiring experience and worth your time for some peace of mind.
nice glad you got it sorted out!
Those bikes are know for the rectifier overheating due to their poor location. Even on say 2017 models.
They do not get cooling air to them being inside that engine cover. The cover has a tiny airflow hole but a rider's boot and pants usually block airflow from getting to the cover's holes.
I know people who made a bracket and extended the wires to allow it to be mounting in open air say on the frame near the front of the engine, or some other convenient place. This made their bike reliable.
Yup remounted mine on the front of the battery compartment. I put it down too low though so it roughed up my front fender a bit so be sure to mount it higher up on that if that is where you put it.
Nice ride sir. Great video!
thanks friend
Yep. Getting ready to do the Mod 3 and change out the stator and rectifier at the same time. 3 birds with 1 stone. I have a 1999 Suzuki Intruder 1500.
This is a big help my intruder is a 99 model is the wiring the same Nate
Same electrical problems with my 05 c90t. Had to have new stator and solenoid in starter. These bikes are notorious for electric problems
yeah they are pretty awful. You are in good company though lol
I can't remember if I said this in my video or not, but this Mod ended up not fixing my problem. I still had to replace the stator, which was definitely the issue. Charged fine after that. Only problem was that I managed to nick my gasket putting the damn stator cover back on (that thing is a PITA) which let it leak oil. I knew the problem but was too lazy to fix it for a few months until I got a new gasket and finally changed it out one day.
Be very careful putting that stator cover back on because it is very easy to damage that gasket. I also recommend using some sort of gasket sealant on top to make sure it is nice and tight. Good luck!
This made my head spin
Great video. I am having electrical problems and suspect this might be my problem as well. I ode my bike the other day for over an hour and then came home and rested for 15 minutes. Went back outside and bike would not start. It never even made a click. Lights did come on fine.
+wvpostal That is exactly what was happening to mine. The lights don't require a ton of juice to turn on so they are about the last things to go. But when the battery starts to get low, it can't turn the engine over so you lose that first. I would say to look at your stator circuit for sure. It is a pretty easy swap. I got mine, I think, from Metric Thunder.
Just a note: The clutch switch will also cause a 'click' and no start on these bikes. It will happen intermittently at first and get worse until it fails completely. I had this going on along with the stator/rectifier issues, so it was a little frustrating. Replaced the switch and fixed all the starting issues. The switches don't last long either. They're prone to fail, but inexpensive, so I carry a spare in my trunk.
@@VTBalla34 Sounds like Rectifier/Regulator is getting super hot. An addition to this mod, with additional wiring is to move that rectifier to the front somewhere near the battery cover box or the oil cooler. (Just don't block the cooler) The Rectifier just doesn't get enough airflow, as the casing design and the "fins" call for.
Yeah I did that. Can't remmeber if its part of this video or not but my only problem is I didn't mount it up high enough so now whenever I go over bumps my R/R smacks the back of the front fender which is kinda annoying and has definitely taken some paint off.
@@VTBalla34check the starter relay. Jump it with a screwdriver across the pos and neg. If it cranks, then the relay is going bad.
Thank you. Great video. Did you save pictures. Bike started up with no problem. I do have a question about the 3 white wires on top.
Did you get yours sorted out?
10 year old video and still helping, thanks for posting! Still have the C90?
i have 05 C90 Suzuki light come on but with not start battery good
What did you end up doing with other 2 non-white wires coming out of the stator housing?
man I haven't watched this video in years. Do you see the wires in this video or are you referring to the ones you have whne you are trying it yourself? If you can direct me to where you are talking about in the video (minute/second mark) I can try to refresh my memory.
Реле регулятор перемістили у передню частину мотоцикла?
Or cut on my bike how do I go about rewiring it and it's a 50cc not a 90
Great Idea , Does anyone have a wiring diagram for this mod ?
Moccs place
I have a 2008 c90. I love the bike. Do about 14k miles per year in Nyc. The only things I hate are the electrical system and fuel tank (too smalll). The reason the stator and rectifier go bad so often from what see from reading up on it is because there is too much heat in that area of the bike. The stator and rectifier are in the worse possible place right under the motor. One mod I am thinking about doing is relocating the rectifier to the front of the bike right in front of the battery. That way it gets better air flow to cool off. The stator cannot be relocated. I am on my 3rd set. So I am really considering the mod. Nice video. Question: how come you didn't relocate it and did the new wired help ?
I did relocate the RR to the front of the battery box. cant remember if I did it during this mod or after when I actually replaced my stator a month or so later. only bad thing is it now bumps my wheel fender when I go over bumps
Do the mod I did great bikes
I didn't see him do anything with the three stator wires. Did anyone else see it.
I ssen this mod also
But wondering does have anything to with n o t getting spark
Thanks
Greg, no, this would have nothing to do with no spark. Your problem is likely your signal generator.
+Ron Judge The wires up on the signal generator could be burnt out, which is one of the known issues that this Mod 3 attempts to fix, but yeah it is probably the signal generator itself.
Where is the R/Rectifier located on the bike?....??
+Young “Bluezuke860” Blue - the r/r is located on left side of bike under the back bubble (stator is located under front bubble). There are 4 bolts to remove, be careful pulling the cover off because the r/r is attached to the inside of the bubble. hope this helps.
+Young “Bluezuke860” Blue Dan Royer is exactly right. You can see this in the video at the 4:36-5:20 mark, and again at the 9:10 mark
I learned I have absolutely NO BUSINESS doing this to my bike by my own hand. I just hope I can find somebody in my area who is a certified electrician who will perform the work for me.
Appreciate your efforts.
Emmm .... Is is no need to be certified electrician to perform this operation. It is very simple electro schema =)
Hello. That stator and rectifier still working good ?
yeah man working great
5 year later update and still all good!
Did it matter what white wire went to what black wire?
uhh yeah
yo tengo la intruder 1500 cc año 2000 y tambien es un problema muy grande alguien sabe de algun foro donde algunos compañeros compartan estas mismas fallas mecanicas que nosotros? apenas me vengo enterando que estas motos son un problema del stator gracias buen video
+Victor Hernandez sorry amigo. No hablo espanol
OK. I am having the same issue and I know for sure it is the stator. Mod 3 was never intended to be a fix for charging but rather an improvement. Read Dr Jones full writeup here:
www.crowitis.com/images/Updated%20Mod-3%20for%20the%20C90.pdf
+tgrbll Actually, Dr. Jones has stated before that it is to address some of the problems with the stator frying out. He alludes to this in the link you posted with: It will increase the ground path for the wiring harness. He (and many others, including myself) believes the grounding circuit is inadequate and results in excess current being provided to the stator, causing premature failure.
Obviously if you have already fried your stator, this would not fix that problem (I was unsure if the stator was, in fact, fried when I did the mod but had planned on doing it anyways so just did the mod while replacing the stator concurrently) but it should, in theory, keep you from having the premature stator failure problem in the future. I have not seen any reports of anyone having a fried stator after completing this mod, so it at least seems to be holding up to theory.
Another issue related to the 'heat' factor is the location of regulator/rectifier. The stock location gets much too hot. Along with Mod- 3, I moved my reg/rec to the front of the bike, and mounted it on the battery box. This keeps it a lot cooler as it gets constant air flow. Many other bike manufacturers do this from the factory. Moving it when doing the mod. involves just making the leads longer. I heat shrunk the leads and used a section of cable sheathing, ran it along the bottom frame, secured with some cable ties. Looks factory and works like a champ, been several years now and trouble free! Note: I also installed a volt gauge on the bike so I can see that it's charging as I ride, again easy to do. I would also recommend using Rick's Hot-Shot stator and reg/rec, both are high output units designed for higher heat than the stock units.
good comment. I did this too but didn't mount it high enough so now whenever I go across a bump the back of the wheel fender bangs the box. not enough to damage the RR but enough to gouge the fender and take some paint off
Hello. How long are you using Rick's parts ? Is it really resolving of C90 electricity problem ?
If the stator plug was bad why didn't you just cut that off and splice the wires to the other end of where it meets . Instead of running wires everywhere and running a fuse .
The overall point of the video was to show the Mod 3 Wiring configuration Dr Jones had developed to increase the reliability and resilience of the entire charging system. This involved cutting the cheap plugs off and soldering the lead together, adding a thicker gauge wire from the starter for less resistance, and relocating the rectifier out of the box and onto the front of the bike where it could get better airflow.
My situation just happened to also have a failed component that I added the troubleshooting and diagnostics to before locating it (it was a bad stator)
no. I need to fix my bike.
You make it so complicated. Just get to the correct way to fix it.
Well it looks like 9 years later the low attention span Tik Tok people have finally found this video. Thank you for the feedback. I will remix this helpful video into a short 60 second clip with no troubleshooting whatsoever (and maybe a catchy dance number) for you useless whiny dipshits.