Battery went flat while out on the road today got the AA out winds out there is no charge coming into the battery, the AA boosted the battery which got me home
took the rectifier off metered the cables there is a Perm pos Red earth Black and 3 whites, there is no viltage coming from any of them traced the 3 whites and they go into a plug and the other end comes from the engine I think from the generator but no power from any of the them and if the battery is removed the bike conks out

the earth cabe going into the rectifier looks burnt and there is a burnt smell from the rectifier where it looks like water has sat in the top of the plug

Any ideas would be greatly appreciated

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My 5th XT660R Mods so far, K+N, Kev Mod, Yamaha Hand guards, Engine bars, Yam Sump guard, Yam Rack, Heated Grips, MT21s, Raised rear XTX dogbones, Front Raised with spacers, Extended Side Stand, Yam Touring Screen, Carbon fibre heel guards, CNC Short Levers, Snorkle Removed, 100W headlight bulbs, Rear pannier rack as rear crash bar CCC oval Cans, Zumo 660 +++

Almost certainly the typical Tenere regulator/rectifier fault.

You will need to either: (a) Replace the loom and the reg/rec unit with OE parts - expensive (unless its in warranty of course). Or (b) Cut off the existing plug on the loom and replace the reg/rec unit with an FZS600 item (eBay) and solder the connections and heat-shrink (or make up your own connector).

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

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My bike did the same and was out of warranty.

There isn't really anything wrong with the rectifier, it's the multi pin connections that are sh*t. If you take the connections apart you will probably see some burnt plastic where one of the pins has had a bad connection. I didn't replace anything, just wired a better connection on the one pin that was obviously at fault on my bike. Sealed it up with a piece of old bicycle inner tube and a bit of insulating tape. Still going strong 4000miles later.

Thanks guys
Yes there is a badly burnt connector, I did re terminate them but still no charge, Ive ordered a new one hope that cures it !!!

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My 5th XT660R Mods so far, K+N, Kev Mod, Yamaha Hand guards, Engine bars, Yam Sump guard, Yam Rack, Heated Grips, MT21s, Raised rear XTX dogbones, Front Raised with spacers, Extended Side Stand, Yam Touring Screen, Carbon fibre heel guards, CNC Short Levers, Snorkle Removed, 100W headlight bulbs, Rear pannier rack as rear crash bar CCC oval Cans, Zumo 660 +++

Hi Adventure Boy, I recommend that you search on the reg / rectifier problem and familiarise yourself with it. You could probably be wasting money / time by replacing the rectifier if the connector on the end of the loom has distorted due to heat build up. I had this on my first Ten and was the first to encounter this problem.
My current Ten started to play up although did not stop or leave me stranded. I just cut the end off the loom and soldered on a Fazer rectifier as per Stoics' instructions. The advantage of this is that there is some 300mm of loom coming from the Fazer unit and using this I relocated the reg under the headlight framework. Works for me. Hope this helps.

I have put a full thread on here describing how and where I relocated the new rectifier.

Cheers SteveD

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If I'm not working, I'll be

You never know....mine packed up but it was the rectifier and not the connector. bought a 3rd party rec and its fine......touch wood!

If it happens again i think i would go for the Fazer one...and putting it under the headlight is a dam good idea.

Cant understand why it was never fitted in that area in the first place mind, as thats where it is on the old 3yf and 4my 660 Tenere's. Especially on a bike thats destined for rough treatment?

Exactly. If you can recall some of the earlier Triumphs and BSA's they mounted them up front, some current BM's mount them on the side of the engine and I believe the XTX and R's are on the side also.
It's just a stupid place along with the stupid samll pins it's a no brainer and I cannot understand why they couldn't use a propreitry item and mount it properly. The bracket that I used is from Adventure-spec and is designed for their Vision X Solstice lights. I have left enough room to mount some perhaps in the future.
I am also in the process of designing a completely new set up for the headlights, using Projector headlights as the standard ones are absolutely hopeless. I did have a HID conversion in the dip beam, but when I hit that pheasant last year it was obvious that nearly all of the silvering had come off the reflector. I do like riding in the dark and will often set off on journeys late at night. I do not particularly likle to have extra spot lights and in my opinion any bike / car that has to have extra light has got bad ones to begin with. The light from the HID was fine for night riding but I want to try these Projector lights as I still have the 'back' mount for the original light which picks up the mounting positions of the frame at the front.

Watch this space!

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If I'm not working, I'll be

make sure you put you multi-meter on AC voltage if you measure the white leads ...

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Riding the Mad Mule !! ... no more... went orange...

Thanks guys hopefully the new regulator will be here tomorrow and Ill get to work Saturday on it will let everyone know what the outcome is

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My 5th XT660R Mods so far, K+N, Kev Mod, Yamaha Hand guards, Engine bars, Yam Sump guard, Yam Rack, Heated Grips, MT21s, Raised rear XTX dogbones, Front Raised with spacers, Extended Side Stand, Yam Touring Screen, Carbon fibre heel guards, CNC Short Levers, Snorkle Removed, 100W headlight bulbs, Rear pannier rack as rear crash bar CCC oval Cans, Zumo 660 +++