Fault Finding the rectification system.

[SheepDog]

Hi guys and merry xmas.

Was out riding in the country the other day when my volt meter was counting down from 13.6V to to 10.6V freaked me out as over 100km from home. Suddenly it started to climb(crawl) upwards but stayed at 12.5V

Got home and have stripped her back and checked generator is giving me 20v idle to approx 60V when revving, and put my meter across the rectifier and readings are what was expected from service manual BUT below are photos of the connector and rectifier and they are damaged. Probably from incorrect coupling together. Broken bakelite supports in the connector and broken barrier on the rectifier. I tried but can't connect everything together appropriately so any possible solutions people would be appreciated! If I get it back together correctly, thinking my battery is on the way out.

I'm thinking firstly, just maybe replace the 6 pin connector as available in the following link (it also list our rectifier SH678A-12 and other similar ones):

http://www.carmoelectronics.com.au/index.php?main_page=product_info&cPath=4318_1083_4776&products_id=2268&zenid=045ol1r5qfg926j4ouup56fub4

As I'm in Australia, anyone know of a place/supplier locally?

Thanks guys   

[T 24]

A few years ago I had that same problem. It was oxidised regulator connector.
All worked after cleaning.
And remember also groundings.

[grog]

Sheepie, reckon a new connector the thing to do. How hard to get to that one, never looked into it. Think id like to check mine, clean up etc. Just in case.

[froudy]

Personally I would replace the wiring loom plug and then try and tidy the chewed up plastic in the reg/rec socket. Use a scalpel to trim the chewed bits away. I would have thought that would sort it out and give you a decent connection...Good Luck

[Irish in Oz]

Try RS Components for new connectors.

[Irish in Oz]

Or Farnell/Element 14

https://uk.farnell.com/w/c/connectors/automotive-connectors-components/automotive-connector-housings/prl/results?st=automotive

[Hooli]

As above, I'd clean that up & replace the connector if you can find one.

This place can probably supply one, but they are in the UK so maybe not much use to you https://www.vehiclewiringproducts.co.uk/

[Irish in Oz]

RS and Element 14 are both in Sydney, I directed to UK site.

[SheepDog]

Thanks for the replies. Will check and add to the earthing strap.

Just ordered the following:

https://www.ebay.com.au/itm/Regulator-Rectifier-Connector-Kit-for-Yamaha-XVS-1100-V-Star-99-02/133010727057?hash=item1ef80ea091:g:IiIAAOSwMv5dEKN5

Due to be delivered between Jan 15 and Feb 20. So I'm off the road until then. Pisser.
I'm pretty sure this is the problem as my battery has charged OK on the bench. 

[Mick_J]

Thanks for the replies. Will check and add to the earthing strap.

Just ordered the following:

https://www.ebay.com.au/itm/Regulator-Rectifier-Connector-Kit-for-Yamaha-XVS-1100-V-Star-99-02/133010727057?hash=item1ef80ea091:g:IiIAAOSwMv5dEKN5

Due to be delivered between Jan 15 and Feb 20. So I'm off the road until then. Pisser.
I'm pretty sure this is the problem as my battery has charged OK on the bench. 

I wouldn't rule it out as I have a battery which shows a good charge on the bench but still wont start my MZ, new battery started it up straight away.

[Hooli]

Batteries need a drop test to check their condition, most car spares places in the UK will do that for free as they hope to sell batteries from it.

[SheepDog]

Guys. Got my new connector for the rectifier/regulator and looking good connected. (arrive quicker than expected).

But Checking the earths and found a damaged and frayed earth wire (black/white) inside my headlight used for the 'Position light' but I have nothing connected to it. Metering checks OK as a ground to the frame and nothing obvious as shortening anywhere BUT I would like to clean it up and it would be nice to know where it starts. Properly lay some heat shrink over it anyway but just asking anyone out there. 

Finalise this before starting and checking original charging problem.

[Eric GSX1400K3]

The position light can be used to run a daytime running light (drl), however in oz we have to have hardwired headlight to the ignition.

I used this plug when i fitted the Stedi LED headlight to run the drl ring of LED's with the low beam.

Where it terminates at the other end of the loom i dont know.

I do use contact cleaner on all connections, plug them back together and then spray the connector assy with wd40 and let this dry. Found this protects the contacts pretty well.

[Andre]

All these B/W-wires splice together in the harness at various places and eventually they terminate at the battery. There is no termination of any wire at the frame. You can measure "earth" or "ground" at the frame because it connects to the engine via the 2 rear engine bolts.

[SheepDog]

All fixed and running smoothly.

I just replaced the connector housing; cleaned and re-used existing crimped connectors (saved me time). I had to reuse the rubber water seal and yellow connector bracket as these did not come with the new connector (even though the yellow bracket was advertised as part of the new part). Anyway ....

The old girl charges well at 14.6 Volts while out and about riding (the Volt Meter attached at the handlebars is a sweet $5 investment). During my down time I cleaned, checked, re-seated all connectors, earths and anything remotely looking electrical on the bike. So far all is sweet and of course better than before (has to be from all my good work)