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

Sorry posted originallyto wrong section by mistake

Yeah Batmam, you are ecorrect. The excess current is dumped to earth and you will find that the pin that corrodes, heats up and disintigrates is the earth pin. On my Ten I cut off the complete block and hard soldered a Reg / Rectifier off a Fazer (same coloured wiring). This item has about 300mm of loom potted directly into the unit. I unwound the loom of the original wiring back as far as the horn junction and connected the new unit to the loom. This gave me a faif amount of extra loom which allowed me to mount the regulator underneath the headlight. No more problems. Job done. A full explanation with pics is somewhere in this forum.
I'll try and find it.

Cheers Steve

__________________
If I'm not working, I'll be

Hey Batmam, thanks for sharing you're findings, I was just wondering what year you're bike is? I thought the regulator/rectifier issues was with earlier models as I have a 2012 built Ten maybe I'll experience similar problems down the track living in a hot climate country?

My bike is 2010 model. I'm not sure if later models do not suffer from this problem but I recommend to get voltmeter installed on your bike. It is small investment you can get one on ebay for few pounds. That is what I did. You can just connect it to battery, you don't need to play with any existing wiring. It allows you to keep an eye on any charging issues and sometimes even warn you before problem become serious-my case.

Righto thanks, I have just fitted an LED voltmeter last week. So will keep an eye on it.

What do you think caused your problem? What accessories where you running?

Sent from my SM-G920I using Tapatalk

I have no extra accessories connected only USB charger that I'm using for my mobile when I'm traveling far about 1x month and little digital voltmeter connected to battery. When I had problem I have tracked some voltage deviations to fan but some were unknown probably linked to dying rectifier. I was also investigating what else could lead to rectifier failure other than heat and bad connection but I did not find anything conclusive. When my previous rectifiers died voltage always went up to 18-20v. Another theory I had earlier was that some rectifiers could be faulty from factory but I believe that on Tenere rectifiers basically cooking themselves alive

I just went on a week ride and on the return leg the temperature was a sweltering 42 degrees Celsius for two days. I have a coolant temp gauge which was sitting around 78 at 100kph in the heat of the day. My bike normally runs about 68/69 @ 100kph.The heat coming off the engine was so intense I couldn't ride with my left foot on the peg. Luckily my bike has highway pegs but try riding on dirt roads using forward mounted pegs...not the best handling position.
It wouldn't surprise me to find some heat affected issues. I will be checking the rectifier connections for sure.
I wish there was some solution to reduce the heat intensity.

Sent from my SM-G920I using Tapatalk

Well, one way is to use a MOSFET regulator. They don't run as hot as shunt style. Google for D'ecosse and triumph and you'll find loads of information

Verstuurd vanaf mijn D5803 met Tapatalk