Xtz 660 2010 Tenere Rectifier Problem, Strikes Again

Discussion in 'Thumpers' started by Beastman, Jul 28, 2010.

  1. Beastman

    Beastman Reaper

    Joined:
    Oct 18, 2007
    Oddometer:
    230
    Location:
    Stanhope, Mongland. Great Britain
    STRIKE ONE..... , heading home from Morocco the bike starting spluttering on in the Riff mountains, Rang Yamaha from Africa which cost a bloody fortune, told them the diagnostic code, ie flashing yellow light on dash, = 46 which points to 12volt issue.

    My mate towed me for 20 miles..... not funny ... infact well scary.

    I swapped the battery over with my mates Africa Twin, but as his battery is a physically bigger and the terminals are on the wrong side ment i had to stand up on the pegs for 60 miles due to the seat not fitting back on the bike.

    Got into Spain, re-swapped batteries, fitting my now fully charged one back on the Yamaha. Managed to get around 100 miles into Spain and the bike stopped again.

    At this stage we were running late for the ferry back to England from Bilboa so I said to the lads " fook it! Yoiu lot go, I,ll get recovered to Yamaha Saville , get it fixed and meet you up in Bilboa.

    Yamaha Saville first said i had a flat battery and thats it, i said no way , its a charging/rectifier issue! they went away and said "yes! " and fitted new rectifier! .......

    Job sorted , set off a happy bear and got another 100 mile back up the road and the bike died again. BUT its now 2230 hours at night , pitch black, freezing cold and i,m pissed off,So i had to push bike 2 miles off motorway and sleep next to it all night.

    Result= recovered next day to Saville,missed my ferry, cost a fortune , bike to be shipped back to UK and i had to fly back!!!! NOT HAPPY.

    Local dealer fitted new loom, bike worked fine, then i sold it not long after, but it was running 100 % and was and sure is still a great little bike.

    STRIKE 2 .....Now i was very impressed with the Yamaha Tenere so I bought another on a year later..ie 5 weeks ago......and last night.........2300 miles later the same bloody problem struck, I took off the rectifier lead and its burnt to a sodding crisp......Now i got next week off and was going to tour Scotland on it ....... not now eh....
    Contacting Yamaha UK to see what they got to say..... watch this space.

    I would,nt care but the bike is bloody great when it runs, but 2 holidays destroyed and a load of agro is starting to piss me off!
    #1
  2. bluesman

    bluesman Long timer

    Joined:
    Feb 13, 2007
    Oddometer:
    3,448
    Location:
    Hoegaarden, Belgium
    not sure if it helps, but check out products by those guys - so far their stuff worked on my mates bikes better than original. Cheap too. I do not know for sure if they have model precisely for new Tenere, but you can contact them to confirm - they always responsive.

    http://www.electrexworld.co.uk/rr98-regulator-rectifier-3330-0.html

    Another improvement can be brought by old trick known to VFR/VTR owners - installing computer cooling fan to improve cooling of RR.
    I think electrex unit + cooler will save you from future trouble.
    #2
  3. Geoff D

    Geoff D Tenerista

    Joined:
    Mar 10, 2010
    Oddometer:
    707
    Location:
    Tenereland, North East England
    I read somewhere about this... might of been the XT660 forum, If I remember rightly the issue is with the plug connector, bad fitting terminals or something.
    Think I better check mine out.

    I'd be so pissed off if I was you, be banging the dealers door down...

    Good luck with getting it fixed for your hols..

    If they can't get the bits for you in time, you can take em off my bike & sort it out when you get back..


    edited to say, just been on XT660 forum & did a search on rectifier.... there's loads of people with the same problem...
    #3
  4. Beastman

    Beastman Reaper

    Joined:
    Oct 18, 2007
    Oddometer:
    230
    Location:
    Stanhope, Mongland. Great Britain
    cheers Geoff, yeah i aint a happy hector!, I,m going to have a week on my Harley now and be a Black Widow for a few days, but if i didnt have the tractor i'd be well hacked off.
    Thanks for the offer of your parts if needed though. Much appreciated. My fear is that Yamaha will only re loom the bike with exactly the same parts! which wont really fix the problem.... just make me think whens it going to happen again?
    #4
  5. Geoff D

    Geoff D Tenerista

    Joined:
    Mar 10, 2010
    Oddometer:
    707
    Location:
    Tenereland, North East England
    Apparently the pins in the rectifier plug aren't pushed in far enough which allows water into the plug... Yamaha MUST know about it cos they've changed loads under warranty... they just not doing a recall.... typical.

    Will be checking mine out tonight... :deal
    #5
  6. dtysdalx2

    dtysdalx2 PITA but useful

    Joined:
    Aug 1, 2004
    Oddometer:
    16,993
    Location:
    Moneyapolis, MN
    Too bad about the wiring issue. But I have had it many times before too.

    R/R's fail. Not sure if it's due to the cheap OEM connectors or internal failure of the regulator section or both. I recently had to cut off the burned wires near the OEM connector (the 3 phase leads) and solder in high temp wire. Still working fine after 1 year. Getting rid of the OEM connector and soldering MAY help, or high temp ring terminals with machine screws may work. Since OEM isn't paying attention you can DIY.
    #6
  7. Beastman

    Beastman Reaper

    Joined:
    Oct 18, 2007
    Oddometer:
    230
    Location:
    Stanhope, Mongland. Great Britain
    Just spoke to Yamaha...... they deny any problem.... have said they'll fix it under warranty but as i said earlier this may happen again.
    I'll get a new loom and rectifier fitted then may look at modding the new kit.
    Shame really cos the rest of the bike is 100%. I hope Yamaha don't sweep this under the carpet or it will screw up the age old fine reputation of the Tenere.
    At least they pick it up , repair it and return it . So they should too mind!
    #7
  8. Geoff D

    Geoff D Tenerista

    Joined:
    Mar 10, 2010
    Oddometer:
    707
    Location:
    Tenereland, North East England
    Stripped mine down tonight... hmmm what a shit idea. The rectifier plug is very similar to one we use at work, they are very difficult to put together... these plugs will be assembled by hand, not a machine.
    If you ride in wet conditions or worse ... pressure wash your bike, you will eventually have problems.

    Gonna fix mine tommorrow night with dialectric grease & silicon, will post some pics.
    #8
  9. Geoff D

    Geoff D Tenerista

    Joined:
    Mar 10, 2010
    Oddometer:
    707
    Location:
    Tenereland, North East England
    So I took my regulator off.... looking at the plug you can see how easy it is for water to get in... you also need to check that all the pins in the plug are pushed all the way in..
    This bike has done 800 miles, never been out in the rain... done maybe 30 miles of damp trails, no mud. Look how much corrosion is starting to set in already :eek1

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    So I got some of this

    [​IMG]

    and filled this..

    [​IMG]

    Then plugged it back in & silicon'd around the plug

    [​IMG]

    [​IMG]

    hopefully I won't have problems with mine now....
    #9
  10. bluesman

    bluesman Long timer

    Joined:
    Feb 13, 2007
    Oddometer:
    3,448
    Location:
    Hoegaarden, Belgium
    as far as I know this lube is conductive. On photo above it looks like it overflows from pin to pin allowing them to shortcut. I think you need to use less.
    #10
  11. Geoff D

    Geoff D Tenerista

    Joined:
    Mar 10, 2010
    Oddometer:
    707
    Location:
    Tenereland, North East England
    On the above pic what you can see is silicone... so its ok :thumb
    #11
  12. Geoff D

    Geoff D Tenerista

    Joined:
    Mar 10, 2010
    Oddometer:
    707
    Location:
    Tenereland, North East England
    Contralube can be termed ‘dielectric’ which translates to - a material which has negligible electrical or thermal conductivity. Although contralube770 may be physically bridging a gap between two separate pins/circuits it will not allow the current to pass between the pins. :deal
    #12
  13. bluesman

    bluesman Long timer

    Joined:
    Feb 13, 2007
    Oddometer:
    3,448
    Location:
    Hoegaarden, Belgium
    yep, found this quote on their website too, you right. Good material, would not mind to buy that lube too. Other ones I used had formed shortcut in high loads situation. But then they state it too:

    "separate pins/circuits it will not allow the current to pass between the pins. Contralube770 has similar conductive properties to air, so if you do not experience arcing/shorting between pins in unlubricated connectors then the addition of contralube770 should not change the performance/characteristics of the component. Obviously, circuits utilising extreme currents/voltages are a different matter. We would recommend test/evaluation of contralube770 before using operationally in all circumstances where extreme currents/voltages are concerned. " - I do not think extreme is applicable to RR...
    #13
  14. Beastman

    Beastman Reaper

    Joined:
    Oct 18, 2007
    Oddometer:
    230
    Location:
    Stanhope, Mongland. Great Britain
    WELL GENTS..... ASSOON ASIT COMES BACK FROM IAN BELLS ,ITS GETTING THE GEOFF D TREATMENT.
    #14
  15. VAN DER BLENK

    VAN DER BLENK n00b

    Joined:
    Jul 7, 2010
    Oddometer:
    3
    Good effort geoff.I have just gone over the 3000 mark no probs but will sort it for peace of mind.
    #15
  16. buzzlightyear

    buzzlightyear Adventurer

    Joined:
    Nov 23, 2006
    Oddometer:
    39
    Location:
    Cape Town, South Africa
    Here in ZA Yamaha did a recall - they basically put insulation tape around the loom and the connector plug, making it water proof. I've ridden in the rain this winter, and have not had any issues.
    #16