QuestionThree wires from Stator into plug to rectifier/regulator, plug melted. The three(3) yellow wires very hot, tried new rectifier/regulator, tested stator, wires still hot when plugged into retifier/regulator. Checked for grounded wires on harness, checked all fuses,all working fine, wondering what is making them hot to touch. Everything on bike works except cooling fan( but works fine running seperatly from bike). What could be the problem?
AnswerHi Dan,
This is a common problem because of the light
gauge wiring Honda used on the stator and
regulator wiring. Also get a snipper and
cut the original connector plugs off, they
are a fire hazard.
Go to a electronics or maybe a hardware with electrical
products and buy a 15 amp connector block.
They are white and you can break off as
many connectors as you will use.
Bare the stator/regulator wires and solder the ends.
Stick the stator wires into one side of the connector
and the corresponding regulator wires into the other side,
tighten the connector screws down on the wires.
High resistance is what causes heat so this will
help reduce some of the heat.
Also if your battery has a bad cell or is discharged
it should be load tested and then charged out of the bike.
The charging systems were not designed to charge
a very low or weak battery.
I will send you a pdf of the charging system,
I want you to get a multimeter and make sure
all the wires are connected and the resistance or ohms
are very low.
Double check all connectors and clean your battery
and/or regulator grounds.
You may have to remove the battery ground from the
frame and file or sand the contacts clean.
http://www.hugedrive.com/published/WG/show.php?q=RFJVSURFQ0s=-9633baa9
If you can add heavier wiring that will help too.
Otherwise use the terminal block to connect the
wiring tightly.
This should help if you do everything listed above
but there will always be some heat due to
the nature of the system.
Excess current is run to the regulator ground so
that always makes some heat.
Also check that the regulator is definitely well grounded.
The green wire should be ground.
Honda connector plugs have been a problem on various
bikes, the VT's and gold wings included.
If everything is very clean, tight and low resistance
you should have lower heat on the wires.
Don't try cleaning the old connectors it won't
work, they have to be trashed, the connections
are just not tight enough. The connector block
has small screws which tighten down on top of the
wires making a solid connect.
Final note:
Check your charging output on the battery
terminals after and make sure the regulator
is doing it's job. About 14-15 DC volts maximum.
Luck!
Wayne S.
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