Massive long shot this, but does anyone happen to know the difference between Yamaha rect/regs 4XY-81960-00 and 6D3-81960-00. 4XY is the original part on the Ten, but I was forced to replace mine with a 6D3 which I got from a Yamaha Marine dealer. They look identical and I assumed the different part numbers were simply due to a different parts catalogue for marine products.

I only ask as I'm trying to source another here in India (yes, this is the first bike I have ever felt the need to carry a reg/rect in the spares box!), and the 6D3 is twice the price of the 4XY which suggests they may be a different spec.

Also, the (second) failed reg/rect has a blackened pin (front left as you look at the finned side of the unit), which suggests to me a loose connection. Is this likely to be the cause of the failure? The connector was fully clipped on and rain/water ingress has not been a factor in the failure. There doesn't appear to be any damage/failure of the connector itself.

Any ideas how I can try and prevent this from happening again? There is very little chance of getting a replacement connector/loom.

Cheers, JD

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...I've just inspected the reg/rect and the connector is now disintegrating, so I guess this is the root cause of my problems. Question is, what can I do to get back on the road?

1) Replace connector. Even if I can get a connector (doubtful), can the original be replaced? There's not much spare loom down there.

2) Cut the connector off and get someone to solder the wires directly to the pins on the reg/rect, and seal up as best I can.

3) Try and get a different regulator and graft it onto the loom as per stoic bloke's mod

4) Give up, fly home, buy a BMW?

Any thoughts appreciated, JD

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i think you know what i'm going to suggest.....

the regulator connector has been the tenere's achillies heel from the start, the earth fails as imho the connector is too small as it has to create a circuit for charging as well as dumping excess voltage to the frame to stop the battery from overcharging.

the fazer600 or fz600 is definately the way to go. straight fit, excess wire to allow joining and the ability to point the wires downward it gets no better!.
though plenty of other makes should do, honda etc. though not kawazaki klr they use 6 wires, the extra one is connected to the ignition oddly enough.

it is really a simple straight forward bit of kit just 5 wires to join properly following the colours, mount it and your good to go!

don't ever mention bmw reliability [or lack off [not a fan!]]


hope you get it sorted soon! bernard

Thanks Bernard, I'm going to look into it today. Will any 5 wire regulator do? There are an awful lot smaller bikes here (125 - 250cc), particularly Hondas, so I think this would be my best bet for an alternative unit.

PS. My mate's 10 year old 650 Dakar has not missed a beat on this trip!

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The Tenere alternator/stator puts out around 300W, so you'll need a reg/rec that can handle that sort of load, otherwise, yes, any 5-wire will do...

Jx

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JennyDakar.com

Hmmm.

I'm not 100% on this, but just thinking aloud.

Marine applications are different and rec/reg assemblies have different applications. Generally a marine application would use a deep cell battery for long power delivery to lights/radio/navigation/safety equipment (etc).

From experience of smaller boats, often they will run at low revs, especially if they are freshwater (where regulations on wake are often in force), so it may well be that this unit is for delivery of power from a generator that can deliver power at lower revs and therfore needs to protect more at higher revs. As I say, I'm just thinking alound and may be way off the point.

I suspect the two units are different, the crux is what it was meant for, it could be a smaller engine where power isn't so important (inshore boats with battiers) or it could be a larger boat where power is more important. To really work out the difference you'd need to know it's original intention.

One thing is certain, the marine produce will be a much more robus unit with better moisture/salt protection.

I have to disagree with Stoic, the weak point on the Tenere is usually the big lump (sorry don't know the technical term) fixed between the seat and the handlebars.....

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Never underestimate the power of stupid people in large groups.

hey are you calling some kind of heel?

eh ??

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Never underestimate the power of stupid people in large groups.

I can assure you that wasting you hard earned on a BMW is a sure fire way to the world of breakdowns and recalls - I speak from experience!!

Not that it helps you, but I pulled my reg/rec connector apart on day 1, covered in in ACF 50 and a poly bag and it's absolutely fine after 5k miles and plenty of mud and sh1te..

A new connector should do the trick as long as there's no reg/rec or wiring damage..

Good Luck..

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Often referred to as the Nut attached to the H'bars..

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