hi guys,just a little something to rattle your brains

i'll start from the beginning, last year i fitted heated grips to my AT and just after fitting them i blew a rectifier whilst they were in use. then during february of this year i blew another rectifier whilst the grips were in use. i decided to disconnect the grips thinking this caused the problem but obviously not as i just went through another rectifier without the grips connected! i decided to check the bike out once and for all!!
stripped it down checking all wiring connections etc and all was in order. i took off the generator casing to find the generator to be discoloured on half of it, so i ordered an aftermarket one locally. it is an electrex generator and when i went to fit it i noticed it's slightly narrower than the original making the bolts too long by about 3mm. i checked the website of electrex and apparently i have the right one for my bike part number g07. so being a bit pi**ed i thought i'd look up price of original. when i went to take the engine/frame numbers i noticed that the engine number starts with rd04 and the frame starting with rd07, is this normal? it's a 2002 model rd07 but is the engine number correct for this bike? it was one owner from new when i bought it with only 4k on the clock. just wondering if this is maybe why the generator is slightly different? any help greatly appreciated as i'm supposed to catch the ferry to spain on the 8th nov so i aint got loads of time!
thanks for any help in advance. kevin

Well, all AT engines are marked as RD04 the change (RD04 or RD07) is on the frames and as I know both alternators are the same. If the problem only is the 3mm longer bolts just cut it. I suggest to check the yellows wires and the socket to the rectifier, Electrex also have a reinforced one made for a company here in Argentina and they use better US Diodes capable to manage highs amps, a good tip is always ride with your lights on to keep the volts down…

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Javier...
Dakar Motos “ ”

thanks for the reply javkap,
thanks for the reassurance on the engine code as i was a bit concerned.
i always ride with my lights on continuously for safety reasons etc, the yellow wires on the new generator are now white are are not connected to the plug(picture) so i gather it dont make any difference which one goes where? anyone fitted an electrex generator to AT?

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Hi Kev, This is a bit tricky this one, so my best help is to advise that you go to http://hondatrailbikeforums. I think they have lists of frame/engine numbers over there. And they are good at helping out with advice.

I hope this link is right and it works cos often my links dont work. (I've just tried it and it doesnt work. Google it?)

I hope you get this sorted - it always happens with a deadline near! Sod's law.

Best wishes

Don’t make any difference which one goes where but keep the good connection, some silicon grease into the plug will be good too.

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Javier...
Dakar Motos “ ”

Hi kevin, sorry can't tell you if the frame & eng numbers are correct but can tell you i had same problem with generator & bolts. I contacted Electrex tech dept and they assured me the gen & reg/rect were correct. So i spaced the bolts with washers & all works fine. Just to clarify, my bike is an 03 rd07. hope this helps, cheers Chris.

thanks for the replies,
thanks to everyone who replied, i will get on twith putting the bike back together on saturday when i get home, thanks chris, i was about to contact their technical department for help! i will sort it on weekend now and let you all know, many thanks kevin.

The engine number on my RD07 starts RD04,it worried me when I first spotted it thinking that the bike had been fitted with an older engine.I was relieved when I found out they all start RD04.
I can't really help with the rectifier but they are prone to failure.Use your lights,keep an eye on the battery,check wiring connections for corrosion.

thanks for the replies guys.
i put generator on with shorter bolts on saturday and all is well.

hope it is anyhow! bike is running fine and showing 14.5v without lights on and 13.8 ish with lights on tickover. hopefully i wont be buying anymore rectifier's! i've put an heatsink also on back of rectifier to take away some heat.connected my heated grips back up and hopefully all is well now. going for a 2wk run on sunday so fingers crossed!
thanks all