Motorcycle Repair: Honda Electrics, honda st1100, regulator rectifier

Question
Hi Jan.  Note I have a 1991 Honda ST1100 which isn't one of your bikes but I believe my question is relevant to all bikes.  It concerns the electrical wiring.  The bike has a CDI unit of which the 3 yellow wires from the Alternator are very burned from overheating at the CDI plug.  I've check the alternator and it checks OK.  Also effected was the Starter Relay switch which I replaced (it had burned wires from overheating.  Now I'm looking at the CDI unit Regulator/Rectifier.  I do not want to replace the unit if possible because of the cost.  However the terminal connections to it are badly corroded and burned.  Spade terminals on the rectifier look great)  The wires from the CDI rectifier to the starter relay switch gets extremely hot.  My theory is that the badly corroded connectors are what is causing the wiring to get so hot to the melting point.  My plan is to replace the connectors with individual insulated female connectors and wire.  So My question is will a badly corroded connection cause such problems or should I look at the expense of replacing the CDI.

Answer
Hi John,

Bad contacts increase resistance which increase heat, etc. etc.  I would say clean all the wiring and use clean terminals if possible.  Then verify the voltages and make sure the rectifier and regulator is working properly, by checking at high revs, the voltage does not go over 14.8V.

Let me know how you get on,

Jan