Great job Sam, You're welcome and thanks for the feedback.
One suggestion, to increase the current carrying capacity of the G pins, donít use the black Rotax plug. Connect the fastons directly to the regulator. This will give you 100% mating contact.
Vanís, Rotax, Ducati, if you are listening...The Rotax 965-349 Ducati 362001 rectifier regulator is not a lost cause, but you need to deal with the design and manufacturing deficiencies if you want to put this behind you;
1) Eliminate the manufacturing induced lead stress on the power components.
2) The potting compound is too soft, and it's unstable over the rated operating temperature of the regulator. (95 Shore A to 30 Shore A)
3) Operating stresses (vibration) acting on the pre-stressed leads (item 1), in a potting compound that softens with temperature (item 2), over time results in PCB solder joint separation failures.
4) PCB connections that were never soldered indicate a poor (or nonexistent) inspection/QC process.
5) Insufficient clearance between an un-fused, high current carrying PCB trace and the rectifierís grounded metal case. The design relies on the insulating value of the PCB's solder mask layer.
6) Poor connector/plug/tab length design. The design of this 22 amp connection only allows about 80% of mating capacity between the connectorís male tab and female AMP fast-on.
7) The material for the male tab is 7.5mm thick, this equals .0295", the AMP faston is designed for an .032" tab thickness. The design falls 8% below optimum thickness.
Last edited by MMiller : 04-22-2017 at 08:19 PM.