Rectifier Problem

[Aussie RE Man]

Hey can anyone help with this one Just got my M model going tonight, the one I've been restoring for nearly the past year. (I'll post some pic's soon) But the two yellow wires coming out of the Rectifier are melting hot!!! I noticed this before i stripped her down last year, so I've replaced the voltage regulator and cleaned all the earths and thought this would fix it, but it hasn't:'( Has anyone come across this problem before ?? Cheers if you can help May be the rectifier itself

[Jess]

Simon,

The rectifier was woefully inadequate from the factory... Your experiance is a common problem.

Given enough time and use ALL Re5 rectifiers WILL fail as they are not a strong enough design.

Suzuki Recognised the problem and made changes during nthe production run, but the Suzuki part is prone to failure and are still in my opinion inadequate.

I have them made, with todays electronics and materials they are much much more durable and to date, I have not had one of mine fail.

Suzuki still lists the part number and MAY still have them in stock... They are 165.00 They later model Rectifiers do NOT look like the original part.

Mine are 85.00. Be aware they do not look like the original part.

They bolt into place where the factory part does, but if you HAVE to have an original, best of luck.

Best,

Jess

P.S. If the connector is melted or deformed on any bike, the Rectifier is on it's way out... Rectifiers work by shunting excess voltage to heat. If your connector is melted or deformed, the rectifier is shunting heat into the wiring harness. This can melt your harness and cause all kinds of very expensive problems...

In my humble opinion, every bike that is ridden regulalry needs to have the recitifer replaced as it is cheap insurance. I have about 8 left, I can have some more made if folks need them.

[Aussie RE Man]

Thanks heaps for the info, it’s a Shame I just placed and paid for a shipment from you this week for other stuff, I could have included one in the order. I’ll see what’s around here, but am sure to end up with one of yours in the end for safeties sake!!!

[shep]

I had the same issues. I replaced the rectifier with one from oregonmotorcycleparts.com/. It helped with the problem, but I still have issues. So, I started testing voltage drops, and found them at various points (kill switch, ignition, etc). So I might end up just rewiring the whole damn thing when I get it back together.