KTM 990 Adventure FH008 MOSFET Regulator Installation

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Thread: KTM 990 Adventure FH008 MOSFET Regulator Installation

  1. #1
    Teenage Moto
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    KTM 990 Adventure FH008 MOSFET Regulator Installation

    This is a mod I've done on a few bikes now and replaces the standard OEM thyristor based shunt regulator rectifier with a newer technology MOSFET shunt regulator rectifier.

    Why upgrade

    The OEM thyristor based units can get extremely hot and have a shorter lifetime as a result commonly failing in a couple of ways.

    The first failure mode causes them to undercharge and, over time, this causes the battery to fail due to it being insufficiently charged long term.

    The second failure mode causes them to stop shunting the excess current and the charging voltage goes through the roof. This can start to pop bulbs, kill instruments and has been known to cause ECU failure (although I haven't heard of that happening on a KTM).

    A major advantage of the MOSFET unit is the stability of the charging voltage. Even at tickover with lights on and fan running, you'll still see somewhere between 13.8 and 14 volts. Just above tickover the voltage rises to somewhere in the region 14.3 volts and stays rock steady throughout the rev range.

    So, upgrade if yours fails or if you want something more reliable than standard with a more stable voltage. Granted, a MOSFET unit isn't guaranteed to stay working but the failure rates seem tiny. I've only heard of two failed units. One was supplied from a breaker in a non-working condition so history unknown. The other was killed by someone connecting the +ve and -ve the wrong way round. They don't like that.

    Why the Shindengen FH008

    This will fit in the standard location and can be wired in salvaging the original connectors off the old regulator rectifier. A used unit can be found from a UK breaker for £60 to £80 delivered and all you need to do is chop the wires off the old unit and solder them onto the new one.

    You can upgrade to waterproof connectors if you wish and if your connectors are completely corroded then you may need to but if everything is in serviceable condition and cleans up well, it's an easy upgrade.

    Upgrading the regulator rectifier on my bike

    My 990 had a Motobatt fitted by the previous owner around 14 months and not many miles ago. It was sluggish on the starter and the Optimate would always charge it at full rate even straight after a decent ride. Hooking up the multimeter showed why:



    Checking the charging system showed it was struggling to get above 13.2 volts at best and the voltage was actually dropping off with increasing revs occasionally dropping below 13v.

    So, I ordered one of these from a breaker:



    Next, I removed the OEM regulator rectifer. I cut the leads off it and removed the connectors from the connector blocks. I cut the connectors off the FH008 ending up with this:



    I ended up completely replacing the +ve and -ve wires and their connectors as the wires were corroded inside and the connectors had seen better days. The alternator wires and OEM 3-way connector were fine and these were just soldered on to give the same length as the OEM unit. All joints were covered with glue-lined heat shrink tubing. You should use glue-lined for covering the solder joints to keep the water out.

    This is what I ended up with:


    ...and that just bolts on perfectly where the old one was without fouling the bash plate unlike the bigger MOSFET units:



    As the saying goes, "the proof of the pudding is in the eating". Firing up the bike with the meter probes on the battery gave this rather better reading:



    My work here is done.

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  3. #2
    The "Moto" boboneleg's Avatar
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    Nice work Alan, I could be winging my way to your house with another bottle of red next winter
    99sleepyhollow likes this.

  4. #3
    The "Moto" 99sleepyhollow's Avatar
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    Quote Originally Posted by boboneleg View Post
    Nice work Alan, I could be winging my way to your house with another bottle of red next winter
    It's a bit far for me

    Crackin job buy the way

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  6. #4
    Teenage Moto
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    Quote Originally Posted by boboneleg View Post
    Nice work Alan, I could be winging my way to your house with another bottle of red next winter
    Make sure you wash it first. Can't have it making my tools all mucky

  7. #5
    Teenage Moto
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    Quote Originally Posted by 99sleepyhollow View Post
    Crackin job buy the way
    Thank you very much

  8. #6
    Back on an RFS again :) KevInYorks's Avatar
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    Go on, Alan.... what bikes have the FH008 fitted? Is it 8A capacity? Is the FH015 therefore 15A capacity?
    Adventure: the pursuit of life. Daniel Roy Wiarda


  9. #7
    The "Moto" Coose's Avatar
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    I can't see the point myself...
    AlanBTL likes this.

  10. #8
    Teenage Moto
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    Quote Originally Posted by KevInYorks View Post
    Go on, Alan.... what bikes have the FH008 fitted? Is it 8A capacity? Is the FH015 therefore 15A capacity?
    According to the Shindengen spec sheet, the FH008 is rated 35A at 14.5v which means it's rated for up to 507.5 Watts. That's safely more than the KTM 990 Adventure kicks out. I've not heard of a FH015 but the bigger units like the FH012 are 50A rated and well over-engineered for the job (725 Watts!). They're just a bit big for the standard location on some bikes (like the Honda XL650V TransAlp, Africa Twin RD04 and KTM 990 Adventure) due to the connectors and so the FH008 is a good alternative.

    One of these will work on any bike with a 3 phase alternator that it will physically bolt onto, or can be made to bolt onto, and that doesn't chuck out more than 507.5 watts as standard. If there is room to fit an FH012 or similar neatly then they are more common and can work out cheaper - but you really need the proper connectors for them.

  11. #9
    The "Moto"
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    Nice job!
    just to clarify the yellow wire are soldered in a like for like position (are they in the same order on both units) and the green and red just are joined two to one and go into the same connectors, as in the photo it seems that the green is not in the white block connector? I'm a numpty when it comes to this kind of electrical wiring thing, can solder though .

    I ask because I will keep the link to the thread in my service/electrical folder on the desktop for future problem solving, then when I come to use the info, you wont be on a two week holiday in Wales with no wifi/phone signal and wont be able to answer the question then
    Cheers, and Bobs bike is always muddy

  12. #10
    Adult Moto Johnny Boy's Avatar
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    Quote Originally Posted by Coose View Post
    I can't see the point myself...


    I can. I see Adventures broken down here, there & everywhere due to regulators failing.

    Thanks to the OP for posting, nicely written and good piccies explaining what's involved. It may come in useful at some time in the future.
    990 Adventure
    250 EXCF

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