Regulator /Rectifier and some wiring

[toshibasz]

hi guys. I'm new to this forum as i just started rebuilding an old tenere. My mechanical skills are almost total beginner and my English is not so good and I would like to apologize for that.

My first question is about regulator / rectifier. Can the old type regulator with five wires (2+3) be somehow swapped with newer one with 4 pins?

My second question is about wiring from the alternator. I have 2 white wires, red, brown, white-red, white-green and green. The last as I understood are for pickup coil. Red and Brown and 2 Whites are for alternator. But according to this scheme, there is no Red red wire from the alternator but there is Black. Am I missing something?




Thank you a lot

[Mezo]

Its easier to see it colour.

We have all the diagrams, manuals & part fiche`s in PDF in the Manuals section.



Main difference on these bikes (XT600`s) is kick start or electric.

M.

[ActionManMelb]

In the above example the two white wires are the AC single phase from the alternator, the red wire is the regulated output to the battery, the rose colour wire is unregulated output (I think) to power the headlamp and other lights, the black is the negative ground.

The four terminal regulator (used on electric start and later bikes) has 3 white wires as the AC 3 phase input, the red wire is regulated DC output and the case is the negative ground.

NOT interchangeable.

[Spoor]

Hi Guys

I'm new to the forum.

I have an '83 XT600 (34L) for which I'm trying to find a replacement rectifier/regulator. Local Yamaha dealer told me they can't help with old bike components, I should find an aftermarket one. Not an easy matter in South Africa.

An experienced XT mechanic however recommended a 4-wire replacement RR (seems like one for a CG125 Honda).

Do you think it will work given his recommended 4-wire colour mapping to the XT's existing 5-wire colours :

XT's Existing RR colour Replacement RR colour
White to Yellow (stator)
White to Yellow (stator)
Red to Red (positive)
Black to Green (earth)
Brown (None)

He gave some explanation of the Xt's Brown wire working through the ignition and that the electrical system will not be affected if Brown is not used.

Will this replacement RR work without buggering up my system?

Much appreciated

[motorang]

Yes.

Andy

[Spoor]

(A belated) much appreciated Andy .

The old RR (OEM part nr 34L-81960-A0) was shot as per standard diode-test. I eventually sourced this Argentine-manufactured OEM replacement (AYA 6060 model) http://www.dze.com.ar/es/producto/2485/ which works fine.

The manufacturer's technical explanation for the present four-wire RR design was very informative (Thanks Martin):

The original (five wire) Yamaha RR design includes a brown wire tied to the ignition switch. The original concept was to guarantee a calibrated voltage of 14.5 (+/- 0.4)V DC on the ignition positive line. The problem with this concept was that as the bike harness starts to deteriorate, there's a voltage drop in the ignition line and the regulator overcharged the battery to compensate for the drop, leading to early battery damage. They suspect in the older bikes the sensor line may cause problems. Their (2485) model dropped the brown (fifth) ignition wire and monitors the battery voltage level directly from the battery positive wire. This is probably the approach followed by similar four-wire replacement models. According to them, if the voltage across the battery terminals @ 3000 rpm is about 14.1 - 14.6V DC you're good to go.