For the last two outings on the Ten I've had the LED show that the connector on the reg was playing up again. Not enough to stop the bike but disconcerting when you are out in the rain!

So to this end I decided once and for all to remedy the situation.

Using the brief from Bernard I got an FZ600 reg /rec and started.........

Pare back the loom to the junction of the horn wires





Cut off the offending connector block and tin the ends of the loom



Similarly tin the ends of the wires on the replacement regulator



Solder ends together. I put shrink wrap on the wires first and then used self amalgamating tape to make it all good and robust.







Check voltage, this is on tickover



I also checked with my heated jacket and it showed about 13.8 volts on tickover and went up to nearly 14 with all loads on.

I was fortunate that on one of my forays over to Adventure-spec I got one of their brackets for the Vision X lights but did not get the lights themselves. The bracket is stainless steel and very robust so I decided to use this.
The loom is now quite long and sufficiently so that I could easily put the reg under the headlight using the aforementioned bracket.



I had to drill two extra holes and you can see the bolts that I put in.



I then removed the screws that hold the top of the radiator to re route the loom and then ofered the unit up.



You can see the new loom crossing to the right of the pic.

......and in the middle of this pic



In this pic I have offered the unit up for mounting but some of the underneath of the cowling is in the way




So I had to cut out to allow space for the unit



Unit now secured and away from the road spray and water etc and in a good place for cooling. I used a couple of old nuts to space the unit off the bracket and clear the clamping bolt heads.I did not know just how hot these things run!



I am very pleased with the result and took off for the evening in the rain up to Dent in the Dales to check all is well.

Heated jacket on full. grips on full and raining, but all running well and so much happier and confident that the bike is much better than standard.

Then this happens........................................... ....................








Hit a pheasant at about 60mph right in the middle of the headlight. Didn't touch the screen or the surrounding bodywork!

PS I was also testing my new Magadan panniers, ssoooooo much lighter and waterproof and my new helmet with Pinlock visor, no more misting up!
.......and my new Primus burner, will take Gas, Petrol or even Diesel!


Waterproof liners






I was coming home and feeling really smug with the Reg mod and being warm and comfortable and running through in my mind this writeup and then that happens. I been in touch with a mate who has a website for bike spares and he can get me a new headlight for about �130. Here's hoping.

I hope this writeup can be of some help to you guys out there.

Merry Christmas.

Steve

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

Great info, thanks. You didn't mention the 'order' of the three white wires - does it matter if they get mixed up?

Did you get a new reg for a fazer?

What age is you Ten?

Thanks!!!

__________________
'10 660 XTZ T�n�r�
London, UK
Geek

Hi J-P-W. The reg was a second hand job - �20. Plenty of them around, basically any of the fazer ones will do as long as they have the 5 wires, three white and red and black ones.

I cannot take credit for this mod as I only copied it from Bernard, but just wanted to move it as my personal opinion is that it's just not right to put sucjh an important item in such a vulnerable position and the size of the pins is just plain bad design.

The white wires can be connected in any order according to Bernard so I just took his advice and did the same.

I kept checking the voltage at all stages of the operation and have noticed in my writeup that I should have mentioned that when revving the voltage will go up to just over 14 when all of my 'appliances' are on full load.
At tickover with them all on it will go down to about 13.6.

I have a Gammatronix LED wired into my bikes' system which shows the voltage output from the battery and it didn't go down to Orange all weekend, which would have indicated less than 13 volts. So a big plus for this mod and I'm happier that it's out of the water spray.

It's worth reading up on some of the other reports on the reg/rec fault and especially Bernards thread.

Forgot to mention the bikes is an '09

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

Good mod and explanation:i

Cool job Steve!

is the pheasant now on the christmas menu? hope so

It doesn't half seem so - considering the reg/rec unit is rated at 35 amp max (IIRC). Google "35 amp spade connectors" then compare the size difference.

Be mindfull of the max rating of the Fazer's unit as I believe it's not as high as the Tenere's. Although IIRC from when I did mine the Tenere's has spare capacity over what the generator produces (to allow for upgraded generator?) Bernard?

hi, what or where are you getting the specs for the ac magneto from? the yamaha workshop manual has it down as 20.8a at 5000rpm unit, to be precise a denso lmx51.

haven't seen any problems in the last 30+k smiles so it seems ok and happy

I"ve done the same mod and same pics on here .Only thing the REG needs an air flow to keep it cool so watch where you mount it .

I have to go with Stoic's expertise on this one but I will reiterate that I loaded the system up as much as I possibly could and was still getting 13.6v at the battery terminals on tickover. That's good enough for me!

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

Hi Bernard,
The specs I was quoting was for the reg/rec not the ac magneto (generator). Also from the service/workshop manual (immediately below the generator specs).
Maybe Yamaha saw fit to use an over rated reg/rec to allow for higher output generator rewinds??