I'm not sure if anyone else has tackled this mod
or not, but I had a go at it this weekend. It's the R/R (Rectifier/Regulator) repositioning mod, which is theorized to strengthen the regulation and charge of the battery by moving it from the under-casing on the bike to the front in order to provide better cooling and air flow.
I decided to try this after having my stator replaced while I was on a long distance road trip several months ago. Because of my situation, I resorted to taking my bike to a Suzuki dealership to have the stator fixed. The final tally was over $700.00 in parts and labor...I couldn't believe it. Had this happened closer to my home, I could have replaced the stator all by myself for about $100.00 and thirty minutes of my time.
Anyway, the stator has seemingly been charging the battery just fine up until a few days ago, which is when it stranded me about 70 miles from my home. I had a guy help me jump start my battery with his car, and I was able to make it back home without further incident.
The next day, I began measuring voltages to see what was going on. The charge to the battery was around 12.5v at 5,000 rpm and 11.7v at idle, so I began to tear her down. I inspected the wiring to the stator and suspected that because the stator and battery were still fairly new, the regulator/rectifier might be the culprit. I gave it a visual inspection, and it appeared to be in decent shape (of course, how could I tell by simply looking at it).
Regardless, I'd heard of this mod and thought that I had nothing to lose by at least trying it. After several hours of cutting, splicing, soldering, and rewiring (the last hour of work actually had me debating whether or not I should have attempted this in the first place), I finally completed the work and got to a point where I could actually test everything out.
My first attempt was an utter failure. Everything came alive when I turned the key and the "on" switch, but then nothing happened when I went to fire it up. My gut had me convinced that I shouldn't have used 10 gauge wire and that it was probably causing to much resistance.
Nonetheless, I went to the battery and noticed that the negative lead bolt was a little loose, so I quickly tightened it up. I then went back and tried to start the bike, and she instantly came alive. I kept the throttle lock on for several minutes and had her idling at about 3,000 rpm.
Finally, I shut her down and attempted to restart it, and the bike fired up with more power than I've seen since I bought her back in '06. I'm not advocating that anyone try this modification, as I'm simply sharing my experiences with you. Regardless, I've put a couple hundred miles on the bike since the modification, and I'm planning a 2K mile trip in September. I'll keep you posted.
Just out of curiosity, has anyone else performed this mod, and what were the longer-term results like? I'm hoping that I've fixed the electrical issues for good, but only time will tell. Also, I don't think that moving the R/R to the front of the bike has improved its looks any...Has anyone done anything creative to the R/R that looks even better then simply affixing it to the battery box (e.g. chrome, a different location, etc...).