Rectifier broken twice

Njones

New Member
Hi! New rider here.
last September, barely a month after getting my 07 FZ6, i fried my rectifier, didn’t figure out it was the rectifier until after replacing my battery and other troubleshooting, but after I replaced it, it ran fine. Until a few days ago, I got the same exact symptoms that I got just a year ago. While riding, check engine light came on, a few miles later, my dash screen went blank. Bike still running, but I pulled over and shut her off. She starts up just fine still, but will only hold a charge for a few minutes before dying. I checked the rectifier and the connecting wires once again are charred and corroded. That’s even with an anti corrosion grease I put on. Is this a common occurrence for these bikes? Do I just have shitty luck? Or is this a sign of a bigger problem that’s causing it to do this?
thanks for any help :)
 

Gary in NJ

Junior Member
Site Supporter
When you say that you used “anti corrosion grease” do you mean dielectric grease? You didn’t put the grease on the pins, did you? That would increase resistance. The dielectric grease only goes on the outer surface of the inner connector - it’s purpose is the inhibit ingress of moisture.

Are you sure that the rectifier wires are the only wires that are charred and showing signs of corrosion? A poor ground connection will cause the premature death of the rectifier.
 
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Njones

New Member
Sorry for the late response I was out of town.
I used a “dielectric grease” it came with the new rectifier I purchased last year, and I did put it on the outer surface of the wires, as well as on other connector wires on the bike and they’ve been fine. So i don’t think it was the grease?
And no I haven’t seen any other charted wires.

And here’s a picture of the charred wires and rectifier

Thank you for your response!
 

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Gary in NJ

Junior Member
Site Supporter
Wow, that's bad. The wire in the top left (second photo) is showings signs of corrosion too. Those wires will need to be traced to the point of origin, depinned, and replaced. If the 3 yellow wires from the stator are burned (and they appear to be) they too will need to be desoldered from the stator and replaced. If they can't be properly replaced, you will have to replace the stator.
 

Motogiro

Vrrroooooom!
Staff member
Moderator
Elite Member
Site Supporter
Personally I would replace the stator as well. There has been some very serious current draw and I wouldn't trust that the stator didn't loose some winding insulation. No grease on the actual connectors in the future.
That connector looks like there may have been a short before the main fuse.
Looking at the schematic I would check the wiring in the wiring harness on the steering triple area to be sure there is not a pinch at the steering stops etc.
One wire was for sure glowing
 
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Njones

New Member
Wow, that's bad. The wire in the top left (second photo) is showings signs of corrosion too. Those wires will need to be traced to the point of origin, depinned, and replaced. If the 3 yellow wires from the stator are burned (and they appear to be) they too will need to be desoldered from the stator and replaced. If they can't be properly replaced, you will have to replace the stator.
Damn well that’s not good news. I’ll check the stator next and hope for the best.
 

Njones

New Member
Personally I would replace the stator as well. There has been some very serious current draw and I wouldn't trust that the stator didn't loose some winding insulation. No grease on the actual connectors in the future.
That connector looks like there may have been a short before the main fuse.
Looking at the schematic I would check the wiring in the wiring harness on the steering triple area to be sure there is not a pinch at the steering stops etc.
One wire was for sure glowing

Will do man, thank you for your feedback
 
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