Mcren wrote: Alright I’ll look into upgrading the the fuse block. Any suggestions for where I should relocate the r/r for cooling purposes? Definitely won’t be able to mount it on the bottom of the battery bracket due to the hole distance difference.
Also I found a diagram from roadster.com for his mosfet r/r he sells, would it be applicable for the SH775?
I always modify the bike to hold the reg/rec under a side cover rather than under the battery just for convenience. But I have to clear out a bunch of stuff to do that. I weld a new set of mounting nuts on the brackets on the side of the battery box. I'll try to get some photos.
For a 3-phase, permanent magnet Kz charging system, that fuse is not a good idea on a shunting 5-wire reg/rec. It would be fine on a shunting 6-wire reg/rec. It should also be fine on a 5-wire or 6-wire series-pass reg/rec, which is what the sh775 is. But because there is a possible reg/rec combination where it would be a bad idea, I generally recommend against a fuse in the output wire from before the battery. The fuse would only protect a small portion of wiring from a short, and doesn't protect anything from a general over-voltage condition as that is not what fuses do, generally speaking. It might protect the battery against a catastrophic failure of the reg/rec, but even Kawasaki did not put a fuse in that particular position.
The difference between a 5 wire and 6-wire is that a 5-wire uses the battery connection as the sensing line. If you put a fuse there, and it were to become open from vibration etc., the 5-wire regulator loses the load on it's output so it's output voltage maximizes instantly. A shunting reg/rec will then shunt all pulses from the alternator. This will quickly burn out the reg/rec and overheat the stator.
A 6-wire will sense the battery voltage is low, so will not try to shunt any pulses so will be safe. A series-pass (like Sh775) will become "open-circuit" so no current will flow and things will be safe.
As a side note on another possible fuse location, even though Kawasaki sometimes puts a fuse between the battery and the rest of the bike and reg/rec, that is also a bad position since the bike may continue to run if that fuse blows or breaks, but regulation will be lost and over-voltage will occur. This has been known to melt wiring, lights, ignitions, and reg/recs... not good.
(Again, let me reiterate, these notes are regarding 3-phase, permanent-magnet charging systems on Kz's. The terms 5-wire and 6-wire would be ambiguous in other contexts.)
In my opinion, the best overall practice for situations where you are not sure if someone might swap out a reg/rec is to put no fuse between reg/rec output and battery. And use a fuse between battery and bike load, that is between the battery and the ignition switch.