Molten Rectifier Wiring.. and stator wire extension loom :-S

New bike only had it a week... Bike isn't charging, I've done all the tests with a multimeter, I think I know what to do, BUT the wiring is melted on the rectifier (aftermarket Electrex RR97) and I could not find anyone else complaining of this specific issue.

Regulator got RED HOT in a matter of seconds when I ran it just.

All brown connectors are in good clean shape.. nothing molten.

Regulator gives 45V at 4000rpm unloaded (discon from reg) - i believe this should be >60V

Reg Rec chart testing gives all correct infinity, 2megOhm or 3megohm readings.

there is what appears to be an extra stator wiring extension loom.. ie another EXTRA set of brown connectors.. seen below

did the stator once have a short stub loom, and joined with that extra connector? then someone has replaced my stator with a newer design with a full length loom to go direct to reg/rec,, but still fit it to the original extension loom??

(yes the azaros are going straight in the bin)



The Melted wiring.. is on the short link tail from the reg rec socket to the 2 flyleads.. as you can see its all gone

Does this suggest a specific problem?

I think its time to rip out the extra long loom.. and send stator wiring direct to the reg/rec pigtail.. obviously going to have to repair those melted yellow wires on the pigtail too.

took apart the pigtail to see whats going on..

I cant work out if its contact resistance thats done the damage, or drop across the wire.. I'm leaning towards contact resistance as the damage is worse towards either end.

BB1000 said:

common problem ..... join the wires by crimp n solder

and the white connector under the rear pod

Click to expand...

So am I allowed to hope that the stator is okay with only 45V output (all 3 phases are equal) as perhaps its been replaced with an Electrex stator alongside the regulator swap (ie perhaps thats a different voltage output)

I'll recrimp/solder and tighten the fly lead terminals.. and remove the extension wire (long 3phase loom) and send the stator wire direct to the flylead.

abrasive pencil all terminals, tighten all terminals, and cover in silicone grease after.

then hope she charges again.

Ohh, white connector? the one with the two red+stripe wires, come from the fuses.. looks like its been put there to allow quick isolation of the battery from under the pillion hump?

I've removed the additional extension wire, cut off the brown plug, crimped and silversoldered some new 6.25mm receptacles onto the yellow wires and locked them directly into the Reg/Rec plug, cleaned all contacts and reassembled. Was 11pm when I finished, so couldn't rev the engine, but from a static voltage of 13.0 it rose and kept climbing past at least 13.5Volts .. so something is happening that looks promising. Will investigate tomorrow if the reg/rec is still overheating.