Electro Sport ESR515 Regulator Review......

[Mike Stewart]

I was having the charge light glowing at me in the lower RPMs, seemed to clear up after the bike warmed up. I also checked the battery voltage with the bike running and it was very close to 16 volts above 4k rpm. I checked the AC voltages and they were great, 22 volts at 1000 rpm, 53 volts at 2500 rpm and 90 volts at 5k rpm.

So I placed an order with Electro Sport for the ESR515 regulator, the good news was it only took 1 day to arrive and was free shipping, the bad news is that it wasn't really a plug and play repair.  Think Heath Kit for "you as old as me" most likely remember, soldering iron, crimps and solder not included. 

I have read that the bullet connectors fit loose, mainly on the yellow wire connectors. Well, all of them fit loose cause they use the same bullet connectors. The only one that is tight is the connector that has the male and female ends side by side. The female connector has hard plastic around it which does not allow it to expand so the connector on the harness side will not push in, no matter how hard you try. Yes, I could force something in it to open it up, but the plastic would likely break (It's that hard). So I ended up cutting all the connector ends off the old regulator and splicing them into the new ESR515 regulator. I could of just spliced the new regulator right to the harness but I think it would be a problem on the road if the regulator went out and I had to do a road side repair. 

The Guzzi connectors are soo much better than the ones on the Electro Sport unit. Their bullet connectors are very thin, easy to spread apart which means easy to compress. There is no way to make a tight fitting connections with these. The Guzzi connectors also push up to one another, with the ESR515, there are gaps showing the bullet connectors slightly, not good!

The last thing I'm not thrilled about with the ESR515 is the wire thickness (gauge) on the yellow and white wires, on the Guzzi regulator, they are at least the next wire size up, time will tell if this is a problem, hopefully guzzi was just over kill on their wire size.

The good news is that the charging light goes right out when the bike starts and it now charges at 14 volts above idle. 

[Lucky Phil]

11 minutes ago, Mike Stewart said:

I was having the charge light glowing at me in the lower RPMs, seemed to clear up after the bike warmed up. I also checked the battery voltage with the bike running and it was very close to 16 volts above 4k rpm. I checked the AC voltages and they were great, 22 volts at 1000 rpm, 53 volts at 2500 rpm and 90 volts at 5k rpm.

So I placed an order with Electro Sport for the ESR515 regulator, the good news was it only took 1 day to arrive and was free shipping, the bad news is that it wasn't really a plug and play repair.  Think Heath Kit for "you as old as me" most likely remember, soldering iron, crimps and solder not included. 

I have read that the bullet connectors fit loose, mainly on the yellow wire connectors. Well, all of them fit loose cause they use the same bullet connectors. The only one that is tight is the connector that has the male and female ends side by side. The female connector has hard plastic around it which does not allow it to expand so the connector on the harness side will not push in, no matter how hard you try. Yes, I could force something in it to open it up, but the plastic would likely break (It's that hard). So I ended up cutting all the connector ends off the old regulator and splicing them into the new ESR515 regulator. I could of just spliced the new regulator right to the harness but I think it would be a problem on the road if the regulator went out and I had to do a road side repair. 

The Guzzi connectors are soo much better than the ones on the Electro Sport unit. Their bullet connectors are very thin, easy to spread apart which means easy to compress. There is no way to make a tight fitting connections with these. The Guzzi connectors also push up to one another, with the ESR515, there are gaps showing the bullet connectors slightly, not good!

The last thing I'm not thrilled about with the ESR515 is the wire thickness (gauge) on the yellow and white wires, on the Guzzi regulator, they are at least the next wire size up, time will tell if this is a problem, hopefully guzzi was just over kill on their wire size.

The good news is that the charging light goes right out when the bike starts and it now charges at 14 volts above idle. 

Yes I found the same issue with the Electrosport connectors.

Ciao