Hi Guys,

I just fixed my rectifier problem and I want to share my findings with you. Many experienced problems with rectifier and as many pointed out problem is usually with connection. I will be bit more specific.

When rectifier died first time on my bike, connector was partially melted inside and metal pins affected with corrosion plus one pin was completely disintegrated. I have blamed water changed rectifier and make sure no water can get inside connector.

I have recently observed voltage spikes down and up (I have voltmeter installed on bike). I checked connector and same pin that disintegrated on previous rectifier partially melted plastic inside connector. I was not out on rain with bike since I have changed rectifier so this damage cannot be caused by water.Also connection to to pin was still solid. I have also noticed that voltage jumping happen only when I'm standing still for some time.

So I think main problem here is heat. When you are standing still for longer period temperature rises. Engine starts heating rectifier heavily. Combined engine and high current heat seems to be is enough to start slowly melting plastic connector. I don't think it happen quickly but over time damage will be significant. Just look where rectifier is placed, it became oven under certain conditions. When plastic is damaged connectors will get loose and also water can get inside. I don't think that bad connection is source of problems, it is side effect of main problem which I think is heat.

I have moved rectifier to different more airy place and since then I have experienced no dodgy voltage deviations and all is working fine. I think I have catch the problem early enough and rectifier survived.

Hope that helps if you ever experience this problem

Thanks