Hi all
About these regulator/Rectifire problems with the xt660z. I would like to sort mine out before it goes, what's the best thing to do to stop it before it happens and if pics are available that would be even better.
Cheers SPOOKYAD

Check the connector and terminals. Make sure its snapped home properly and use some dielectric grease on reassembly. Then pray!

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Grease the inside, outside or both.

Everything!

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Go for a 10 mile ride, stop the bike & make sure there is no heat build up in the wires at the regulator, if the wires are warm/hot to touch replace the terminals in the electrical connector, apply dielectric grease.

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Mods that I have done to my XTX's

My 04 XTX
Stage 1 & 2 DNA filters / Kev fuel mod / snorkel mod / Drilled air box mod / Engine breather mod / Fork Spacer mod / 15w fork oil /
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My 07 XTX
Raptor 700 cylinder 102mm / Modified Crank Case to take a 105mm Raptor Cylinder / 11:1 102mm JE Raptor piston / Stage 1 Raptor Hot Cam / Ported head / Colder Spark Plug / +2mm Throttle body / DNA stage 1 & 2 filters / Modified Air Box / Snorkel removed / Worry Brothers stage 2 filter cover / 6mm & 8mm Bolts Replaced with Titanium Bolts / Recovered seat in Black / O2 Eliminator /

My 09 XTX
59HP at the rear wheel / Stage 2 Raptor Hot Cam / DNA stage 3 Air Box / Carbon Can Exhausts / Modified Exhaust Link Pipes / PCIII With Custom Fuel Map / Wideband Commander O2 Data logger / LCD100 Dyno Jet display & fuel adjuster / 2500 OHM HT lead instead of a 10K OHM XT lead / Extra Coolant Cooler / Protaper Fat Bars / Tail Tidy With LED Tail Light / OKE Protection Knobs / LED indicators / AIS blocked / Modified rear sprocket rubbers / Rear Foot Pegs removed / 09 ECU With 02 Sensor Changed To A 06 ECU / Complete wiring harnes Changed from 09 to 04 / Home made LED resistor flasher / Hole drilled in the fuel tank filler neck to allow quicker filling / Modified Bar End Weights / Progressive front fork springs, 15W fork oil, forks lowered 25mm, used XTR rear links lowering the rear 20mm, rear spring one click stiffer / Changed front & rear guards from blue to black / 47T rear sprocket / Speedo Healer V4.0 / Kev throttle cam mod / Throttle grip mod / The new 2010 O2 sensor mod is out, works a treat, The new 2012 O2 Controller is out, PM me for details

Now ride a 2018 MT09SP ABS + TCS

My KTM 990 SMR Mod book. http://www.ktmsmt.com/viewtopic.php?f=13&t=4946

Thanks guys will have a look.

Loom and Rectifire replace, today 4 years after my Tenere was built, and all covered by Yamaha Warranty:-)

The work will be completed next week, meanwhile i'm running on a black Tenere (free of charge....)

Today the shop started to strip down my bike to replace loom and rectifier


Old Connector, notice that the yellow frame is missing, it has melted together with the rectifier...


New Loom :-)


New Rectifier


Old Rectifier (with the yellow frame from the connector..

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Yamaha XT660Z Tener� 2008
"If everything seems under control, you're just not going fast enough" - Mario Andretti

she will run sweet again

fair play to Yamaha for replacing the parts after the two year warranty has ended

zoom zoom

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Ride On :tenere:Camel 2008XT660Z
harvey mushman did it in the dirt Uma 1994 TT250R

Yamaha Sweden has extend the Warranty with 3 year so we have 5 year warranty :-)

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Yamaha XT660Z Tener� 2008
"If everything seems under control, you're just not going fast enough" - Mario Andretti

That 5 year warranty is a double edged sword, we have it here in Norway too. On one hand I want to fidget around and learn to fix things on the bike myself, but on the other hand since we have 5 year warranty we may as well use it

Chili, how did you first notice the regrect was failing?