40 Amp (dual 20) system on an early XR4

Here's dual 20 amp regulators mounted on a 1988 XR4 engine. Note the custom mounting plate. It is mounted where the "advance" module used to live. The "heavy" red wires are 14G fine stranded, tinned, double insulated conductors going to the trolling battery bank. One regulator charges the starting battery. The other regulator charges the trolling batteries. The two battery bank negative terminals are bonded together with a 6G jumper. I carry a 3 foot 6G jumper with two clamps on it for emergency starting off the trolling battery bank.

I replaced the original rectifier with a small terminal strip. A wire with a bullet connector on one end and a ring terminal on the other takes the tach signal to that strip, and the original tachometer wire takes it from there forward.

Re: 40 Amp (dual 20) system on an early XR4

The AC connectors to the regulators charred within a year of installation. The bullet connectors are good for about 10 amps, and are being required to carry 20 amps at full output. Over time they will overheat and open up.

Re: 40 Amp (dual 20) system on an early XR4

Connectors cut out and wires stripped. Note the copper wire is discolored. It will be fanned out and scraped bright before it's twisted into a connection.

Re: 40 Amp (dual 20) system on an early XR4

The connections will be insulated with adhesive lined heat shrink. Here's one source.

Re: 40 Amp (dual 20) system on an early XR4

A 2 inch piece of heat shrink in placed over the regulator wire and pushed out of the way. The wires are twisted together, ready for solder.

Re: 40 Amp (dual 20) system on an early XR4

The wires are soldered, and ready for insulation.

Re: 40 Amp (dual 20) system on an early XR4

The heat shrink insulation is slid over the connection and heated to finish the job.