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Burnt Rectifier/Regulator Pics and question.

1556 Views 7 Replies 5 Participants Last post by  thwwx
4
Here are some pics. Of what I believe to be the problem with my 1st Gen R6 shutting off after 30 mins of use.

Typical symptoms included: Gauges flickering before bike dies, will not bump start, battery needs charging.

Question:
Because I've cut the harness off, and replaced it with another, does the order of the 3 white wires matter?

I didn't keep track of which white wires go where. :curse :banghead :help

Also, just to verify, this rectifier is toast, and I need to replace it as well yes?

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Yeah, it looks like its toasted, same with the rectifier

Same shit happened to mine last summer. I cut the harness off an 03 then got Scott (Fathom1) to install it to an 05 rectfiier.
You can test the regulator with a multi meter.

I wonder what causes this, some foreign matter catching fire, or shorting a connection?

I think I'm going to coat my connector in some dielectric grease.
I don't believe the order of the 3 wires matters, it's just the black/red. Now I'm not 100% sure, but close. Just make sure you test the charging system after you hook up the new harness.

As for the rectifier, you should be ok using that one. I've had the same problem and continue to use mine w/ no problems (I just spliced some new wires (thicker guage) on and moved my rectifier to the side of my bike for more airflow). I don't know if the newer ones generate less heat or not, if so, it might be worth it to pick up a newer one.
Hey thanks for everyones replies.

I assume the rectifiers are also interchangeable between the different generations?

Im just guessing that the newer ones are more reliable than the old no?
Joko is right, only the red/black matters, the 3 white wires do not matter as they are the 3 phase AC coming from the alternator.

Do not coat the junctions with dielectric grease. I did it and regret big time. My onboard voltmeter gradually showed a voltage drop as the heat causes the silicon grease to migrate and coat all mating surfaces. Bike could not pull to top speed. Problem went away after cleaning away all the grease, which was a bitch to do as it has spread from the heat.

The reason the junctions fry is because the contacts come loose with time. This in turn cause contact resistant and arcing, generating heat at the point of resistance (the loose connector). It's almost always the red/black that frys because they're high current-->more arcing. Contact grease will further interfere with good conductivity although they're great at keeping water/moisture away. Water is not the issue here, it's poor contact, so shove a screwdriver into the individual connector and make the female end 'close up' so that it grips super tight on the male end (rectifier end).

The Yamaha stock connectors come really loose, so I suggest you guys do this pre-emptively, it will save u the trouble of hunting down a plug that will match the rectifier.
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thwwx said:
Joko is right, only the red/black matters, the 3 white wires do not matter as they are the 3 phase AC coming from the alternator.

Do not coat the junctions with dielectric grease. I did it and regret big time. My onboard voltmeter gradually showed a voltage drop as the heat causes the silicon grease to migrate and coat all mating surfaces. Bike could not pull to top speed. Problem went away after cleaning away all the grease, which was a bitch to do as it has spread from the heat.

The reason the junctions fry is because the contacts come loose with time. This in turn cause contact resistant and arcing, generating heat at the point of resistance (the loose connector). It's almost always the red/black that frys because they're high current-->more arcing. Contact grease will further interfere with good conductivity although they're great at keeping water/moisture away. Water is not the issue here, it's poor contact, so shove a screwdriver into the individual connector and make the female end 'close up' so that it grips super tight on the male end (rectifier end).

The Yamaha stock connectors come really loose, so I suggest you guys do this pre-emptively, it will save u the trouble of hunting down a plug that will match the rectifier.

Great write up!! :handclap

For me it was the red wire. It turned black so you cant tell which one it is.

Regardless, Is the rectifier shot then? or can it still be used? Juding by the pictures I would assume its finished no?

Thanks again.
:hattip
Surprisingly, the rectifier is ok for many cases. There's a how-to on recrimping the wires with regular connectors, doing away with the stock 6 connector socket.
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