The temporary repair to the rectifier wiring managed to get me through another 1500km in Morocco but it gave out just as I got onto the boat at Tanger. The bike's in a dealer in Algeciras who says it needs a new rectifier. Yamaha have agreed it's a warranty job and it's going to take 10-12 days to do, so I'm flying back to the UK and will come back later for the bike.

We agreed on the rectifier part number (4XY-81960-00) from the PDF parts manual. But looking at the attached pics it's clear it also needs a new socket which isn't listed.

Does this mean a whole new wiring loom?

Attached Images

	rectifier.jpg (32.5 KB, 94 views)
	rectifier-socket.jpg (47.6 KB, 105 views)

__________________
"For sheer delight there is nothing like altitude; it gives one the thrill of adventure
and enlarges the world in which you live," Irving Mather (1892-1966)

Access the Morocco GS Knowledgebase

I believe so.

__________________
I spent a lot of money on travel and racing motorcycles - the rest I just squandered.

XT660Z - Commuter, Adventurer...Racer?

www.dashmoto.net

Other bikes >> MT-03 / CG125BR-J / ER-6F
Departed >> ZXR400L3 / EC300 / DR-Z400E / DR800S / GPZ500S / GS400

As Dave says, yes......


I'm fairly happy that there is nothing wrong with the loom or reg/rec assembly and that this problem is more to do with assembly. To connect the two items there is a double click, and the problem is when the two are pushed together until only a single click is made. In this case the bikes still works (I've tried it) but the connector isn't sealed correctly.

In all the cases where people have had the loom replaced, there's not been another problem.

Personaly I think if it happened to me now I would cut the connector and put a different Reg/Rec in it's place (I'm past any warrenty work), in your case you'd be better off letting them replace the loom IMHO.

__________________
>-------<

Never underestimate the power of stupid people in large groups.

My loom has been replaced under warranty. The mechanic told me he would just cut off the connector and mount a new one, but Yamaha did not want him to do that.

+1

+ 1 yep been there and done that!

i used a s/h fzr 600 regulator i purchased off ebay for �14 inc postage, i did not require it and still have warrenty, i just did not want the hassel of a failure. its happily been working for the last 7000 mls.

its fitting is in the heroes prep article

bernard

I agree, sometimes going to get a warranty parts or doing warranty work on your bike is a real pain. I also don't bother about my warranty much, unless the part is expencive.

The other day my radiator cap packed up so I bought a new one online & fitted it myself, just a pain to book your bike into the deaker to be told we have no stock & you won't have your bike for a few days & have to walk home.

__________________
Click here to join the XT Supporter's scheme

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 /
[
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