Hi All,

Apologies I guess many think this has been done to death!!

Looks like I have the classic reg/rect failure, engine management light on, flat battery no charge etc.

The multi plug on mine looks as if it has welded itself together (I assume all you are supposed to do is squeeze the tang on the side of the block and pull?)

Bit concerned that many appear to have had replacement looms under warrantee, I assume this is due to the build up of heat from the bad connections causing damage to the wire?

Has anyone managed to get away with just cleaning the contacts up and resealing?

Should have vaselened it all up when it was new like the smart guys!!

Full dealer service history so will speak to them to see if they will do anything as it's a known problem but in the meantime any comments would be appreciated.

Thanks,

Adrian.

Which multi plug is this one? The one under the seat?

My engine management light is on too, but the battery gone flat because I installed a gps tracker device for too long without ride the bike, now, looks like is charging normally.

Hi,

The multi plug I can't get apart is on the reg/rect itself, on the front down tube of the frame near the horn.

You can't get apart because its a combo relay?

You should be able to get it apart. Almost certainly you have the reg/rect problem. The only "cheap" fix if out of warranty is Bernard's (stoic bloke)...

http://www.xt660.com/showthread.php?t=17054

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+1

I agree, I had the original Ten that broke down, that one also had the replacement full loom. What a load of bull. The problem is that Yamaha in their infinate wisdom decided to remodel the actual rectifier and you will note that the pins inside the rectifier 'pocket' are considerably smaller than on either the X or R models. It always seems to be the Earth pin that heats up and melts the connector block.
I now have a small Gammatronix LED on my front cowling that shows me the output from the battery. If this indicates less that 12V I can stop and check the reg connector.
So far no problems but if it did occur I would certainly do Bernards mod and move the Reg up under the headstock.
Hope this helps.

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If I'm not working, I'll be

Thanks All,

Hopefully the loom will be ok and it will be just a matter of sorting the connection block or going for the Fazer unit.

I guess if it's moved it needs plenty of airflow around it to keep it cool.

Anyone know if the bad connection kills the unit?

Gammatronic LED an excellent tip, thanks!

Yeah, this little gizmo is cheap and shows you the info you need, undercharging, overcharging etc. Everyone should have one!

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If I'm not working, I'll be

Can someone confirm that the REG/REC is down at the front of the bike ? It seems an odd place to put it !mine has a metal plate in front of it to stop stones etc smahing it to bits is this standard .What conections should i check and was this fixed by Yamaha on later bikes mines a 09 model .cheers

Yes it is down there behind the metal plate. Silly place for getting wet, but the unit's alloy casting acts as a heat sink so it does need to be in relatively fresh air.

Just check the pins inside the multiplug (sitting on top of the unit) are clean and there is no scorching. Make sure the plug is fully home when refitting. Buy some dielectric grease designed to protect the terminals inside connectors, use liberally, for a few quid its well worth investing. Not sure Yamaha fixed anything really? General concensus of opinion is the faults that showed up on early bikes were due to poorly seated connectors. I guess they just do a more conscientious job of fitting the plug in the factory now and dealers are more aware of checking it!

(+1 on the Gammatronix LED too - first mod I did on the bike)

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