I'm currently at a motorway service station waiting for recovery as the ten has broke down. Was going down the motorway when the engine light came on, then about 25 miles later I got a 4k error code, then the needle fell to zero and stayed there.

Carried on and the bike was chugging, just about made it t the services. Slowed down and stalled, hit the starter and you get......click,click,click,click. So totally dead battery.

So.....I take it I've suffered the reg/rec problem?

Certainly sounds like it...I hope Yamaha are aware of how regular this is occurring.

Yep, it seems like yet another regulator failure.

That's a real arse. I assume you must be well out of warranty as your bike's a Khaki one? Looks like you might have to start trawling eBay for an FZ600 reg/rect unit and so the Stoic mod.

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Nice to know the symptoms if it turns out the way we all think... I just received a second hand regulator in the post yesterday from a Fazer(thanks for the info Stoic) so the only thing to do this week is to test that it works and stash it somewhere on the moto...perhaps under the rear of the seat using the existing elastic rubber that is there?

I hope you get it all sorted out...keep us posted as whether it was that or something else?



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The Suit:What would you consider to be your greatest weakness?
Me: Honesty.
The Suit: Honesty? I don't think honesty could be construed as a weakness.
Me: I don't give a f**k what you think.

.[IMG] [/IMG]

Just got home via the AA,.going to charge the battery and hopefully get the hike started then test it to see if its charging (im not good with elecs)

I had read about this failure but I didn't realise you got the engine light on 1st, and then a 4k error code?

Best read up about this mod a bit more then, I actually have a fazer but its thou not a 600.

Is this a problem with the Ten only, or does it effect R & X models also??

Not aware of any problems on R/X? Probably because the reg/rec unit is in a far more sensible location on these models!

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right then.

Took the rec / reg off this morning, looks fine....no corrosion or damage. the plug also looks fine. before my scotland trip i had taken it apart, covered in ACF50 and made a little cover out of an old mountain bike innner tube to go around the plug.

i charged my battery and popped it back in.

With the ignition off the battery said 12.74
started bike, let iddle for 5 secs and it was 13.86v
left it for 8 -10 secs, now said 13.89v
reved it and the voltage dropped RIGHT down, couldnt read it as it was just falling numbers.
now its iddling again its reading 12v
revved again, same thing - major falling voltage.

SO....am i right to assume the actually reg/rec is knackered? also is the plug supposed to "clip" into the top of the unit? mine doesnt...it just pushes down on and then stops...no click feeling if you know what i mean.

also forgot to mention that when i pulled over due to this problem i could smell burning from engine. saying that though i had been riding all day at 75mph.

Talking off riding all day...i also noticed how quick the oil breather fills up. 2 to 3 days of all day riding (on road at 70mph ish) and it was full, is this normal?

any advice welcome as i now ****** all about elecs!

From what you are describe (if all the terminals are OK), it would seem unlikely the fault lies with the alternator, as it can produce the necessary voltage (well almost @ 13.8V), although not consistently (which �could� mean intermittent loss of one of the three phases in the alternator itself, but very unlikely). The remaining possibility that can give rise to correct voltage at tick-over and reduced voltage at higher revs is an open diode fault (failure of one of the bridging diodes) in the rectifier, which also cause the loss of one phase on the AC side of the charging system. This then causes the regulator to see a reduced reference voltage as engine speed rises, which in turns causes the regulator to reduce alternator output current (effectively it inverts everything).

So to cut a long story short, I�d have a stab in the dark that you�ve got a partial rectifier failure, which is why you are seeing some signs of charging, be it erratic and a bit weird, the regulator is probably OK. However, as the regulator/rectifier unit on the XT660 is combined, it of course means that to all intents and purposes the whole thing is shagged!

Bear in mind the above is of course only an educated guess! I would suggest your best course of action would first be to try and find a donor reg/rec unit to try out on your bike to confirm things.


BTW my oil breather fills up about the same as yours - don't get anything in it when riding the back roads, but as soon as you hit a constant engine speed for any length of time it fills up.

As for the connector it should click home, but I must say mine has less of a pronounced click these days due to dielectric grease, ACF50 etc I've used on the connector! Pull it though and it shouldn't come back off (without releasing the tab).

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cheers for that.

So am i right in thinking that people dont buy OEM reg / rec as there crap......instead they replace them with a Fazer 600 one?

I'll replace it and then take it from there i guess. Is there anywhere i can find out what voltage readings i should be looking for.....so X amount at idle, X amount at 5k revs e.t.c