Don't forget it MAY be a simple knackered battery!

I had exactly the same problem with one of mine - went through the obvious (alternator, coil, reg, etc) above and problem still present.

The nearly new battery was fading under load.

Replaced it with a better German battery and problem sorted.

I have the pdf manual thanks.
Drain oil, remove cover, remove stator bish bash bosh job done . When the gasket arrives.
Bad battery would not give the dodgy resistance readings across the stator.
I can put my gazebo up in the back yard for a bit of cover . that's what I bought it for. 8 foot wide yard. 8 foot wide gazebo with fence walls !!

Let you know the results next week.

Min

yes, it's the stator..

1-Put the bike on it's side remove the small e-start motor cover as there is ONE bolt in there that you need to take out and can only access from there!

2-Remove the stator coveruse a screwdriver that fits perfectly on the bolts or you will strip them!

3-If the gasket is damaged, replace it with a new one! I also used a very thin layer of liquidgasket on both engine part and stator cover!
If you put some on the engine part, it will hold the new gasket perfectly in place when you put the stator cover back on!

4- When you're putting the stator cover back on, be careful not to crush the neutral cable between the engine part and the stator cover!

Keep in mind that the regulator/rectifier might also be faulty, so check it out!
And the battery is probably wasted aswell.... get an AGM battery or one of those Li-on/Lipo whatever batteries: Lithium Ionen Batterie Yamaha XT 600 E '90 '03 HJTX9 FP | eBay

Vando ;)

I agree with Jens - possibly the Rectifier/Regulator. I had the same problem on my 4pt. I put a new Rectifier on and now its fine, worth trying first as its a cheap and easy fix costing from about £15.

Dan

Tested the new stator and compared it to the one still in the bike . It is the stator going by the multimeter.

Thanks for all your replies,
Min

theoneandonlymin don't forget to follow the steps I mentioned in order to replace the stator and get it right at the first try ;)

Hi,
If it helps I had exactly the same problem on my 43f........rev the bike and lights dim and battery was flat as a witches t*t
Changed the reg. rectifier and after 6 weeks battery charges and all electrics work.
I bought mine from a company in US called caltric.....super service.
Mark

How are you getting on??
 

When used correctly multimeters tell the truth that is invisible to the naked eye. :thumbup1:
The logic/flow diagram for fault finding assists of course.

Just poking about in the internet, I came upon this, which collaborates your flow chart:-
Must-do Tips BEFORE installing a Rectifier/Regulator
Check the AC output of the stator
Check that the stator is not grounded.
Replace any burned or corroded connectors on stator & rec/reg
Check & repair any melted wiring
Use hi-Temp Dielectric grease on all connectors

found here:-
http://ricksmotorsportelectrics.com/...ier-regulators

No! I've already told him how to check for a faulty stator and he found it!
It only takes two steps to check XT for a faulty stator and I mention them in one of my previous posts!

And from what he tested, one phase of the three phases is faulty!
Yes, the regulator/rectifier COULD also be faulty and it is also possible to check if it is good or not with a digital multimeter.

Grrrrrrrrrrr
 

A few days later than anticipated but wish that I had a chance last week.
Drain oil , cover off , remove stator, clipped the wires to aid removal . The screw holding the wire shield was that tight the head sheared off ! Never mind.
Put the old rotor beside the new. Wrong size !!!!
New stator : 115mmx54mm
Old stator : 103mm x 42mm
Of course Electrex is shut for the weekend.
This one is the same size ;
Electrex World - Motorcycle electrical parts for Japanese, European & British bikes | Electrex World Ltd G73
Is this correct or do I wait for them to tell me on Monday???
I was sent a G45 .
At least I have a few spare days to sort it.

Secondly when I took the cover off there was an O ring loose inside the flywheel. Not mashed up. There was one on the cover as well where it should be. Where did it come from ?

Min

Im pretty sure the boltholes for the xtz660 doesnt match the xt600 :(

I seem to recall I had both a xt600 and a xtz660 stator on my table at the same time, they looked very simular, but wasnt identical.

The xtz660 would be awesome though, theyre about 280W.

This reminds me of an old saying in woodwork/joinery: - measure twice, cut once.

Never mind, progress consists of two steps forward and one backward, per day.

Wemoto.com seem to sell the G73 for the XT . 103x42x16

Does this definitely mean that when I speak to Electrex tomorrow it is definitely what I need ?

Min

Call Electrex and tell them the measurements of your stator, how many cables and the plug it comes with and they should exchange that one...

Thanks,
I have just emailed them and it should be no problem.
Whilst I had a miute I looked at the wiring coming out of the stator. In behind the heatproofing one wire was burnt through and detached and another was suffering a wee bit. Ah well out with the soldering iron. Soldered 3 new wires onto the solid parts coming out of the stator.
Out with the meter onto the new tails
1.2 1.2 and 1.2 !!!!!

Flipping heck, do I throw it back in this afternoon or is it not to be trusted ??
Give it a try maybe that is what I reckon.
In fact I am just heading down to do that now.

What about the mystery O ring that was inside the flywheel ??? Just noticed on the workshop manual where it is from.

Min