Question about 1978 Yamaha XS 650 E

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I bought a 79yamaha xs650e used and it wasn't charging. I checked the brushes and they looked good, I replaced my stator and then I replaced my 7 wire rectifier/regulator that the previus owner had already replaced, and it still wasn't charging. I then noticed in the work shop manual that the rectifier and regulator are two different pieces, do i need to buy a regulater, and a diffrent rectifier or can i make the new rec/reg that i just bought work? the new i have is 7 wire. going to one harness it has a green wire and brown, that plugs into my bike but that plug has a green brown and black wire. in the other harness coming From the rec/reg are a red, blk, and 3 white. i havent changed out my steel screws on my stator for nylon one yet, is that something i need to do?

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  • justinjmo Jul 12, 2010

    I bought a 79yamaha xs650e used and it wasn't charging. I checked the brushes and they looked good, I replaced my stator and then I replaced my 7 wire rectifier/regulator that the previus owner had already replaced, and it still wasn't charging. I then noticed in the work shop manual that the rectifier and regulator are two different pieces, do i need to buy a regulater, and a diffrent rectifier or can i make the new rec/reg that i just bought work? the new one i have is 7 wire. going to one harness it has a green wire and brown, that plugs into my bike but that plug has a green brown and black wire. in the other harness coming From the rec/reg are a red, blk, and 3 white. i havent changed out my steel screws on my stator for nylon one yet, is that something i need to do?

  • justinjmo Jul 12, 2010

    My 79 xs650e is not charging. I replaced the Stator and checked the brushes, battery ok, cleaned the router, and I bought a new aftermarket 7 wire, 2 harness rec/reg I went to put it in and the wires didn't match up. Main harness had a red, black and three whites, and after moving them around I got those to match up. The smaller harness had brown and green wire. The bike has 3 wires in the harness green, brown and a black wire. Does this mean I need to get a different rectifier that has 2 black wires? Or can I make this one work? In the work shop manual it shows that my rectifier is separate from my regulator. Could that be my problem? I also seen on the internet some people replacing the steel screws on the brushes with nylon screws is this something I need to do?

  • justinjmo Jul 12, 2010

    My 79 xs650e is not charging. I replaced the Stator and checked the brushes, battery ok, cleaned the router, and I bought a new aftermarket 7 wire, 2 harness rec/reg I went to put it in and the wires didn't match up. Main harness had a red, black and three whites, and after moving them around I got those to match up. The smaller harness had brown and green wire. The bike has 3 wires in the harness green, brown and a black wire. Does this mean I need to get a different rectifier that has 2 black wires? Or can I make this one work? In the work shop manual it shows that my rectifier is separate from my regulator. Could that be my problem? I also seen on the internet some people replacing the steel screws on the brushes with nylon screws is this something I need to do?

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The voltage regulator is a seperate component from the rectifier. If you have checked and replaced most other things, brushes, rectifier and such, then the fault must be in the Regulator asembly. You should check this first with a volt meter, to see what, if any voltage is coming out. A new regulator asembly is very expensive, at about $150 +
There is no need to change out the steel screws on your stator for nylon ones. This does not affect the problem you are having. You need to fit the correct Rectifier, then check for voltage coming from the Regulator, located somewhere near the battery, under the seat or behind one of the plastic side plates.

Posted on Jul 13, 2010

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Have you checked the battery for dead cells? Instead of replacing all these parts again, try replacing or at least checking the battery cells to see if any are dead cells. If there is a dead cell in the battery it doesn't matter what you change it will never charge and it will give you the same symptoms of having a bad rectifier or regulator.

Posted on Jul 12, 2010

  • James Young Jul 12, 2010

    If the Wires in the unit you have don't match but the plug does it will most likely work. It is not uncommon for something like this to change in the after market parts area. What used to be 2 parts is now 1 assembly but the connections are the same and work. If you told the person you bought the parts from what you needed and what year and model bike you had then he most likely gave you a compatible part. If the plugs don't match up then you will most likely need to get a different part unless you have the pin outs and have the ability to change wiring harnesses. This all assumes that your problem isn't the battery to begin with since a dead cell in the battery will cause your charging system fault light to come on. I had an officer do the same thing you are doing changing all these parts and when I tested his battery it had a bad cell in it. I changed the battery and all the problems went away. He spent over $200 in parts and still didn't have it fixed. I spent $30 on a battery and 20 minutes later the bike was fixed.

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Did you check the output with a meter and it said read the same battery voltage with the engine on and off. ?? have you tested the battery yet. ??

Posted on Jul 12, 2010

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You will have to go for your model rec/reg and that will help. the new model harness is not supportive to your model.It will not give proper support to control the regulator to regulate the voltage as well as current. the steel screws on your stator is nothing to worry off. Thanks.

Posted on Jul 12, 2010

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https://vserv09.fein.bawue.com/spc/index.php?r=item%2Flist&id=8141
You can use a simple continuity tester to see if the field (stator) is good by checking continuity in each winding.
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1982 Yamaha XJ 550, the battery will not take a charge. New battery, checked all connections, ran all the tests (stator, brushes, and alternator). Replaced the voltage regulator/recifier. Not sure what is...


It is corrected properly, right? + to the wiring harness and - to ground ... right? Are you certain about the rectifier? Is the battery charged at this time?

You know a alternator cannot make power unless you first put power into it ... right? Alternators (unlike most generators) are not self exciting. If your battery is weak or "dead", the alternator cannot make electricity to charge the battery. I don't know what the rating of your alternator is. Your battery should be fully charged before you do any more tests. If you have a 1 amp charger, allow at least 10 hours for a full charge. Don't cook your battery with a big, powerful, fast charging automotive battery charger.

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