Infamous CBR 600rr regulator / rectifier problem

[Vtec44]

Apparently, it's pretty common with the all F4i's, 2003, and 2004 CBR 600RR. The rectifier will over heat and won't charge the battery. It happened to me on my 2002 F4i after riding on local streets with the high beam on for a while. For the 2003-2004 600RR, the solution is to purchase the rectifier from the 2005-2006 model and replace your old one (remember to also purchase the mounting bracket). According to RonAyers.com (http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/1/Make/Honda/YearID/46/Year/2005/ModelID/6504/Model/CBR600RR/GroupID/272484/Group/WIRE_HARNESS), the 2005 600RR rectifier's part # is 31600-MEE-003, mounting bracket part # is 31605-MEE-000.

This is the direct link to the 2005 CBR 600RR wiring harness http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/1/Make/Honda/YearID/46/Year/2005/ModelID/6504/Model/CBR600RR/GroupID/272484/Group/WIRE_HARNESS

[laga56]

Hey Vtec....I'm new to the forum and this is my first post. I have an 04 CBR 600RR and I've been having the battery problems that seem to be realted to the rectifier that you mentioned. I'm just curious if you know the steps involved in replacing the part. Is it as simple as replacing the rectifier and the wiring harness or is it more involved? Thanks for the help

[Vtec44]

According to the fiche, there are only 2 plugs so you just unplug the old one and plug the new one back in. The mounting is different, so make sure you get it to. I didn't replace the one on my old F4i, but moved it to a more ventilated area.

[laga56]

thanks a lot. I'll try moving mine first. I know this is a silly question, but do you know exactly where it's located in the bike? Is it near the battery?

[Vtec44]

thanks a lot. I'll try moving mine first. I know this is a silly question, but do you know exactly where it's located in the bike? Is it near the battery?

On my old F4i, it was mounted on inside of the tail fairing so I moved it down and out so air can circulate around better. On the 600RR, it's already mounted in front of the radiator (left side) so it's getting plenty of air. It gets too hot at time and the old model rectifier wasn't able to handle the high heat. They redesigned it for 2005, that's why you should replace it whenever you get a chance.

[laga56]

awesome....thanks for the help

[Vtec44]

no problem! :)

[whitebamboo]

How can I tell if my rectifier is bad or if I just have a dead battery that won't hold a charge any more?

[Vtec44]

I'd assume you can test it with a volt meter, after it has been fully charged with a 12v charger.

http://www.yuasabatteries.com/faqs.asp?action=1&id=30

[Chas4RR]

The rectifier/regulator failure has been a common problem for a long time - on the VFR's of the late eighties and nineties even.

To troubleshoot, it helps to have a schematic and a voltmeter. Using battery ground post for neg side of meter (meter in +DCV mode), measure input voltage to recitifier with bike running. Stator/alternator should be putting out better than 14 volts with engine at steady rev above 3K rpm at input to rectifier. If that's good, move to output side of rectifier or even to plus post of battery. Rectifier should regulate excessive voltage of stator down to about 13.5V (typical) with engine at steady revs. Below a certain rpm (near idle), rectifier will switch off as there is not sufficient voltage being generated at low rpms to charge battery. So basically, you should see two voltages at low/high rpms at your battery if rectifier is doing its thing.

[Dr. GoFast]

i have an '04, 14,800 miles, same battery for all its life, no problems :dunno . are you sure they didn't fix it for '04 as opposed to '03? seems like something they would've taken care of after a year of development? i'm only gonna do this if it proves to be a problem.

[Vtec44]

If you don't do a lot of stop and go riding then it shouldn't be a problem. On my F4i, I didn't have a problem until close to 18k miles of a lot of stop and go riding in traffic. My 03 600RR track bike is absolutely fine as far as this issue is concerned. If you don't have an issue with it, leave it alone. Even if there's a problem, you can still bump start it most of the time.

[hmmmm16417]

I have an '06 and i'm having this problem . I can still bump start it but that's getting to be a pain in the a$$! Long rides it's fine. short rides around town..... battery dies in about 3-4 starts. grrr!

[Dr. GoFast]

figure out a way to get more airflow to it, you must be obstructing the flow somehow. it's weird that i've never had a problem with my '04 which just turned 15,000 miles and you're having probs with the '06 supposedly "updated" part.... are you still under warranty? if so, let them take care of it for you.

[Vtec44]

On the 600RR, it's mounted right on the side of the radiator which pretty much getting all the air you can. Yeah, the 05 - 06 suppose to have an updated design. As far as I'm told, it's a defective design on the 04 and below.

[hmmmm16417]

figure out a way to get more airflow to it, you must be obstructing the flow somehow. it's weird that i've never had a problem with my '04 which just turned 15,000 miles and you're having probs with the '06 supposedly "updated" part.... are you still under warranty? if so, let them take care of it for you.
I just picked it up used a couple months ago actually. I highly doubt it's under warranty. The guy I bought it from needed to sell it so the credit union would give him the loan for his harley. So, I ended up getting it for $5k, it has 10k miles.
I can see the rectifier if I look through the left mid fairing, I can actually touch it easily. I thought it was a bad place for it right behind the radiator since the header pipe is right there too..... I had thought about relocating it?
it only acts up when it's hot and I do a couple short rides in a day.

[Dr. GoFast]

NICE DEAL! hmm..... does it get air where it's at? yea, well if it had a warranty, he would've given it to you with the purchase i'd think (it's a good selling point). i don't know what to say man. if it gets air it shouldn't overheat. i guess get your multimeter and service manual out and start doing some troubleshooting :dunno . does it only shut off when idling at a stop for a long time or what?

[Vtec44]

I just looked at mine, you can make an extension out of aluminum sheet to lower it below the radiator to get more air.