6th Gen Rectifier On A 5th Gen, With Pics!

OK, so when my Regulater failed somewheres about BFE Utah, i kinda knew what was going on from the posts around here. It failed on the regulating side (was still rectifying) and the voltage went high. So i turned EVERYTHING ON. The headlight switch in between settings to get both on, the right blinker, the GPS, the radar dectector, the inverter, the helmet cam, the video camera, and sometimes when it went near 16, i rode the rear brake pedal ever so gently. That worked. A pain, and it pissed off alot of people with my new patented superbright lights, but hey... oh, the speed limit signs reflected so bright i had to close my eyes to pass them, they hurt.

Every so often the voltage would creep up, so i would stop and leave it all on, but kill the engine for 5-10 min. that worked to kill the batt pretty good.gave me like 25 min of running...

Near Grandjunction CO, i find a real truckstop, and buy a 12v thermos. rated at 10 amps with a cigeratte lighter socket. So i plug it into my tankbag where i have a radio shack 3 into 1 lighter thingy. With just the low beams on, i am now at 12v running. ( i Had my multimeter leads taped into the radar dectector plug and it in my tankbag)

So i am moving again but now with a thermos bungeed to my sleeping bag on my rear seat bag, and making tea!

http://www.vfrdiscussion.com/forum/index.p...i&img=16287

This works great for the last 30 miles that night to my hotel.
So i am really tired, check into a crappy motel, and low and behold no shampoo. I thought i could count on that, but no. So i think, if i open the window, maybe the cool air will let me skip the shower. then randomness strikes me as i find a tuna sandwhich in the window. it doesnt smell yet, and the bread seems soft. i debate eating it till i findthe black spot. i am really tired from my ordeal so far.
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http://www.vfrdiscussion.com/forum/index.p...i&img=16288
http://www.vfrdiscussion.com/forum/index.p...i&img=16289

I walk to to get food and shampoo that night at a hotel (bike wont work without luggage and thermos... ugh) and end up with toffee peanuts and an odwalla drink. After a shower where i have to jerryrig a hanger to hold the drain in the shower open, i think ti myself, that odwalla needs to be refridgeerated. Then BAM!!! There is no fridge, thats how that tuna sandwhich got there. If anyone happens to hit the Palomino motel in Grand Junction CO, and gets room 112 ( i think) dont open the window, its still there.

The First 30 miles the next day it all goes smooth then to hell (in that order)when i suddenly spike up to 17 volts again! Turns out the cheapo thermos has a thermostat and it just kicked in. So i call my buddy in Co Springs while i have cell service (who is my emergency plan) and he asks " what would happen if you left the top off?"
So like a smarta&& i reply, "It would spill out!" Then i realize he is exactly right. The added evaporative cooling effect of 75 mph will make it very hard to keep tea at its full temp overcoming the 120 watt heater element. so i leave the lid off, change the water for colder water and off i go.

I stop every hour or so just in case and dump ice and fresh water in the thing, just out of paranoria. It steams the whole way into my destination.
YAY!
So now what you all have been waiting for, the rectifier swap!

I call everywhere, decide i DONT want to mess with an aftermarket one, or the stock one. A quick search of the 6th gen forum shows a distinct lack of Rectifier failure threads. Perfect.

The 6th gen one is cheaper anyway by about $50. I order one through APex motorsports in Co springs (BIG DEALER!) and have it overnighted.

It is much heavier, thicker, and more confidance inspiring in every way. It also came with longer bolts and an aluminum backing plate.
http://www.vfrdiscussion.com/forum/index.p...i&img=16290

http://www.vfrdiscussion.com/forum/index.p...i&img=16291

http://www.vfrdiscussion.com/forum/index.p...i&img=16292

Now as was posted here, it is silimiar but has an extra black lead, beefier, and BIGGER alternator connectors. The dealer tried to tell me the stock one was fine and 3 dealers all said they HAVE NEVER heard of one failing. Idjuts. I wanted to give them mine with 6k miles on it and tell em to suck it, but hey, im a nice guy, i dont do that kinda thing... So HONDA KNEW it was a problem, since every issue we have with the 5th gen is improved. better heat dump capability, better internal circuits, bigger connectors to the alternator where some people have burnt them up.
http://www.vfrdiscussion.com/forum/index.p...i&img=16293

http://www.vfrdiscussion.com/forum/index.p...i&img=16294

So you can see the diff... took a jewlers screwdirver and popped all the connectors off both units, put the output connector from the stock on on the new rectifier (same) took the black wire and extended it and soldered it to a heavy red lead that went to the batt positive (fuel pump fuse feed wire?) and soldered and heat shrnk the 3 alternator wires to 4" extensions and to the yellow wires going into the new rectifier.

It bolted up perfectly with the new bolts and alum plate to the existing holes. My fan however was more than i wanted to deal with since it didnt fit nicely against the new rectifier, so i removed it. I thought, hey, the 6th gen ones dont fail from stock do they with no fan?

SO i fire it up, and at 1500 roms cold i get 14.3 volts. I let it warm for a min and i go to 7k rpm.

14.3 volts

so i hit the high beam and rev it from idle to 10k

FOURTEEN POINT THREE VOLTS.
no jumping, no variance, nada.

NICE.

Oh, i also got the only 6th gen unit Honda showed in stock in the new world, which also made me feel good knowiing if they failed more, they would stock more. fing02.gif

I also put in a new battery for good measure since i still had the original one.

i got the 60$ agm battery from batteries plus, ya i know it says 45 on thw eb, but the stores are franchised and charge whatever they want.
http://www.batteriesplus.com/pc-32748-59-X...%20BATTERY.aspx

Wow, great post. Entertaining (can't believe you passed on the sandwich) and informative.

I have a 2000 and as far as I know it has the stock rectifier in it. Sounds like upgrading to the G6 is the way to go. Do you think the fan will fit with some adjustments?

Also, when you have a chance, will you please post photos of your wiring mods? That would be a great tutorial for those of us on the board wishing to dodge the bullet on melting our wiring!!!

Again, excellent post. THanks for sharing. Excellent photos, too!!!

That is the same regulator that you get when you order the upgraded regulator from honda, and it has the right connectors on it. Paid $120 from service honda I think.

Steve.ski, Aug 31 2006, 01:45 PM
Wow, great post. Entertaining (can't believe you passed on the sandwich) and informative.

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The 6th gen have the RR mounted up front, don't they? So there's a lot more flow of (cool) air around the RR to help it cool down. I hope this 6th gen RR will do the trick for you, at least it looks beefier.

V4 Rosso, Aug 31 2006, 07:49 AM
+1.gif
The 6th gen have the RR mounted up front, don't they? So there's a lot more flow of (cool) air around the RR to help it cool down. I hope this 6th gen RR will do the trick for you, at least it looks beefier.

Well, i didnt see where it was mounted on a 6th gen, maybe someone with one could post that pic?

I forgot to take pics of the final wirnig because i was working in the realy hot sun, and just wanted to go ride...

As for if thats tha same one you get for the updated 5th gen, i dunno, but the extra black sensing wire is a nice touch which means different elctronics inside. Remember, the output wires and internal guts could get got and give a false reading, with a no-load sensing wire, i think it does a better job of maintaininf voltage consistantly.


Also, its $50 cheaper.

And if it came with the right connectors for the alternator, you would probably just plug it in, which still leaves you open to the connector melting in the future.

As far as where the wire went to, there is a red wire in a red sleeve tied to the battery positive terminal with the main battery cable. i just trimmed back some insulation down a bit from the connector and before the fuse where it was comvenient (without cutting it), tightly wrapped the new wire around it, and silver soldered it. a bunch of electrical tape later and it all looked good.

The fan i had was the same size of the old unit and it fit flat against it, i think i may try a smaller CPU fan mouted on the front end blowing lengthwise in it. If i bothered to make some standoffs for the old fan, it may fit, but it would be close. That and a CPU fan will have a better velocity than i was getting out of the Box fan which i think would be better again.

captainchris13, Aug 31 2006, 12:16 PMWell, i didnt see where it was mounted on a 6th gen, maybe someone with one could post that pic?

On VTec it is mounted on the right side of the bike on the frame just after of the steering head.

jeremy556, Aug 31 2006, 09:54 AM
On VTec it is mounted on the right side of the bike on the frame just after of the steering head.

IS that an area that gets good airflow or stagnant air? If it is good flow, i suppose i will have to go and put the fan on mine for safetys sake. Ill have to get to that when i get back home since i have a bunch of those things attached to old motherboards in a closet.

Thanks!

Chris

captainchris13, Aug 31 2006, 10:58 AM
IS that an area that gets good airflow or stagnant air? If it is good flow, i suppose i will have to go and put the fan on mine for safetys sake. Ill have to get to that when i get back home since i have a bunch of those things attached to old motherboards in a closet.

Thanks!

Chris

Yes, that area on the 6th gen gets pretty decent air flow. Plus, it's mounted to the frame (which acts like a giant heat sink) and not to the sub-frame. I would probably put a fan back on yours just to be safe. fing02.gif

Great story! I love the part about the thermos. Good thinking. beer.gif

Damn, that was sorta quick thinkin'.

I just replaced my RR for a cheapo Rick's. Have no idea how long it will last. The thing runs fricking HOT!

I have no idea how normal that is. The failed one was the upgrade from original.

If it goes again I'll try the 6th gen RR. Thanx for the idea.

chris2992, Aug 31 2006, 08:44 AM
That is the same regulator that you get when you order the upgraded regulator from honda, and it has the right connectors on it. Paid $120 from service honda I think.

I was quoted $220. Average price from all Honda shops here in Las Vegas.

I think I love yous guys <<sniff>> What TERRIFIC timing, mine went yesterday.

PS- $145.49 from Service Honda. SWEET, sweeter than $220