[ishan12]

This issue with RR unit is quite common. I guess many Inty/ GT owners have faced this. Mine had the same issue of engine malfunction and ABS light going on and off and occasional power loss at 80kph and above. The RR unit was replaced under extended warranty and it never reoccurred again.

[2StrokeJunkie]

RE has put the RR unit behind the engine between the swing arm pivot and the engine mount. The RR unit by nature heats up which is why it has fins to act as a heat sink but the position that RE places it in causes it to overheat and fail. RE has not changed the RR unit position even on the new 650s. This is a common issue with many owners reporting it and mechanics who work on 650 know of this issue, some even change the mounting position so that it gets more air flow allowing it to run cooler. Really can't figure out why RE hasn't found a fix to this.

A rectifier is a device that converts an oscillating two-directional alternating current (AC) into a single-directional direct current (DC). The rectifier constantly charges the battery through power generated from the magnet and coils, while the battery is also continuously being discharged in order to provide power to the ignition, fueling, lights, etc. This conversion of electric power causes the RR unit to heat up and when it doesn't work well the battery voltage and recharging capacity drops leading to loss of power supplied to the ignition, fueling and other components. This is what causes the bike to perform erratically when the RR unit starts malfunctioning.

[CLASSICREBORN]

Happy to hear that your issue has been sorted. Always glad to see issues getting resolved and the rider returning back happy.

[ThePatientMan]

Hi @iabhimanyu - i own a 2019 Inty baker express which i have ridden for approx. 20,000 kms till now. I have had multiple electrical issues with it as the first gen Inty's were plagued with faulty electricals specially the Rectifier units. The local dealer personnel couldn't diagnose it properly both time i took my vehicle to them.

First time is was mis-diagnosed as a dead battery (as the bike was showing the red battery icon for somedays prior to it refusing to start one fine day so i also was kind of convinced that it was the battery). Had to call for Roadside assistance and get the vehicle towed to the service station.

The problem (refusing to start) again cropped up two days after i got the bike back from the service station. I really lost it and shouted back at my advisor and got him to send someone to take the vehicle back to the service station. In the two days that i rode the bike it developed a new issue - The engine used to shut off when slowing down (even with the clutch lever fully pulled in).

This time it was again a mis-diagnosis and they claimed that the EVAP canister was clogged and they replaced it (i had to pay for it). With the issue cropping up again after a couple of days i finally reached out to an RE engineer working at the Chennai plant who send a local service engineer to the workshop and the issue was finally diagnosed to a faulty RR unit. My aftermarket LED Headlight bulb was replaced with a RE halogen unit (which was the culprit it seems as it was mis-drawing power as mentioned by @AtheK in his post).

Inty's been doing fine since then.....Hope the above was helpful.

[iabhimanyu]

Originally Posted by ThePatientMan

Hi @iabhimanyu - i own a 2019 Inty baker express which i have ridden for approx. 20,000 kms till now. I have had multiple electrical issues with it as the first gen Inty's were plagued with faulty electricals specially the Rectifier units. The local dealer personnel couldn't diagnose it properly both time i took my vehicle to them.

First time is was mis-diagnosed as a dead battery (as the bike was showing the red battery icon for somedays prior to it refusing to start one fine day so i also was kind of convinced that it was the battery). Had to call for Roadside assistance and get the vehicle towed to the service station.

The problem (refusing to start) again cropped up two days after i got the bike back from the service station. I really lost it and shouted back at my advisor and got him to send someone to take the vehicle back to the service station. In the two days that i rode the bike it developed a new issue - The engine used to shut off when slowing down (even with the clutch lever fully pulled in).

This time it was again a mis-diagnosis and they claimed that the EVAP canister was clogged and they replaced it (i had to pay for it). With the issue cropping up again after a couple of days i finally reached out to an RE engineer working at the Chennai plant who send a local service engineer to the workshop and the issue was finally diagnosed to a faulty RR unit. My aftermarket LED Headlight bulb was replaced with a RE halogen unit (which was the culprit it seems as it was mis-drawing power as mentioned by @AtheK in his post).

Inty's been doing fine since then.....Hope the above was helpful.

Even I was told to replace the ABS sensor. At one point they even said that the fault might be with the ECU unit. Thank goodness I found right solution here and I insisted upon changing the RR unit first. Which they did and now she's running fine.

[iabhimanyu]

Originally Posted by CLASSICREBORN

Happy to hear that your issue has been sorted. Always glad to see issues getting resolved and the rider returning back happy.

I am so so glad too. Though I am still at the back of the head worry a little while riding her that the issue might resurface again. It will take some days for her to regain my confidence haha

[CLASSICREBORN]

Originally Posted by iabhimanyu

I am so so glad too. Though I am still at the back of the head worry a little while riding her that the issue might resurface again. It will take some days for her to regain my confidence haha

Yes, it is obvious that it will take some time for you to regain your trust. But I am hopeful that the work has been done well. Ride safe.