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Cali 3 right hand switch

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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 07:52
Originally posted by Gianni Gianni wrote:

The solid state regulator can be bought cheaply in a number of places. It is a Lucas NCB403 equivalent.

Thank you very much. Missed this bit. Very kind

Ian
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Brian UK View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 08:00
Check things like the three yellow wires from the alternator. If they are still in reasonable condidtion, why not use them again?
Don't make more work than you need to.

Those chocolate block connectors were probably used to replace a multiway connector that wasn't connecting too well.  It might have been possible to put a new proper connector back, depending on what the wires are like, and whether the other end has been messed with.

Just trying to simplify your task.


Edited by Brian UK - 31 Jul 2020 at 08:04
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Richard Hyatt View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Richard Hyatt Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 08:03
The wires between the stator and rectifier have to be capable of about 33 amps .
If I remember correctly, the VWP had 33amps wires.
The wires between the rectifier and control box can be a tiny bit less.
It's the yellows that carry the bulk of the amps to the r3ctifier.
Make sure you've got 33amps wires from rectifier board to battery pos and neg as well to get the charge to the battery
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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 08:34
Thank you makes sense. Cheers. 

Now then confusion reigns even more. 

I’ve got a voltage regulator and a rectifier as seen above, but when I look at my wiring diagram for a carb Cali 3 I don’t have a rectifier showing. 

When I look at the link for the Cali 3 Brian kindly posted it also does not show one. 

The plot thickens, on the link for the Cali 2 it does show one. 


So now my head has just exploded, what a bike I have

Any ideas or come across this before

Cheers

Ian
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Gianni Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 08:58
Ian, you have a Bosch alternator, rectifier and regulator system in hand so the wiring diagrams are moot at this point.

Here is a link to a number of alternative wiring diagrams by Carl Allison http://www.thisoldtractor.com/guzzitech.dk/gb_en_technical_wiring-charts.htm

The caution is that some are incomplete, some are USA spec, some do not reflect production line changes, some are wrong, and some are probably perfect but cannot reflect what a previous owner may have done. But they may give you some clues as to what you can achieve with what you have.

Do you have a basic ohmmeter so you can check the alternator rotor and stator, and the rectifier diodes?
Le Mans 1, Spada, Cali 1, T3 Mongrel, Le Mans V, Quota x 2, Stelvio TT
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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 10:29
I do I have this one 


But apart from checking a battery I know not how to use it. 

Cheers

Ian (neophyte juicer under training)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 10:34
Ian, I did say the Cali III would not have the Bosch alternator as standard, so don't look at those diagrams. In fact so much of your bike is different to the Cali III would lose those diagrams completely.

Use the Cali II one for the alternator and when you get round to the ignition, use the Spada 1000 one I linked to earlier.


Edited by Brian UK - 31 Jul 2020 at 10:38
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 10:41
Originally posted by Richard Hyatt Richard Hyatt wrote:

The wires between the stator and rectifier have to be capable of about 33 amps .

Why, The alternator he showed in the picture is clearly labelled 19 Amps. And being 3 phase, those yellow wires will never individually carry 19 Amps AC.
The original wires for the alternator have always proved adequate, why change things you don't need to?
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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 10:46
Yup

One diagram is frying me poor brain I think more is a step too far for me, very kind though and I can see how it would help with the various components. 

I’m ordering all me bits today and when they come I’ll just start out building it all up, there are quite a few cobbled and chopped bits on the harnesses so I suppose I will need diagrams for the correct colours and where they go presuming it may be different, but think I’ll cross that bridge when I come to it. This is an epic for me now and all I wanted to do was copy the harness with new wires and connectors. 

Ha ha such an adventure 

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Ian (neophyte juicer under training)
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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 10:49
Originally posted by Brian UK Brian UK wrote:

Use the Cali II one for the alternator and when you get round to the ignition, use the Spada 1000 one I linked to earlier.

Roger that Captain
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 11:16
Assuming you won't be able to get a sufficient range of colours for the wires, it might be a thought to put some sort of marking on each wire as you make it up, save any confusion - now which blue wire was this?

Peugeot wiring harnesses (and possibly others) have a 4 digit number stamped on each circuit, so all you need to look for is the number on the wire. They are coloured too, but there is not a sufficient range of colours.
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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 11:25
Good idea

I wanted to order it all in one go but looks like I may need some differing colours as I go along. 

I have seen some sticky numbering things on VWP so I’ll get some just in case

Great idea though

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Ian (neophyte juicer under training)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ken-Guzzibear Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 11:48
very good idea to add heat resistant sleeving to all the alternator wires gets hot in there do you have a plastic collar that fits behind the alternator cover, if not get one ...Alternator spacer it helps with cooling 
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Ian T View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ian T Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 16:09
Indeed I do and I have ordered some heat shield stuff as you suggested 

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Post Options Post Options   Thanks (0) Thanks(0)   Quote c13pep Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 2020 at 16:44
I would have thought the alternator/ regulator/ rectifier wiring for the Bosch parts was standard throughout the Guzzi range with only the length of the wires being different. My Monza uses the same Bosch parts as did my v50/3s and all had common colours for the looms etc.

CHRIS 
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