Stator connector smoking while running

[isaac]

So I found out my bike was slowing down because it wasn't charging today, traced the stator wires to a connector to the left of the battery, then found out that the stator side of that connector was melted.

There were three wires that were formerly attached to the connector, but they were all separated now because the connector melted. I pulled them out not knowing this at the time, and didn't know how they went back in.

That is to say I didn't know how they are arranged. They're all yellow, all the same spade type connector, so they're indistinguishable.

So I said what the hey and reconnected them wherever and started the bike up. It charged at 13.xx volts the whole time which was good, but pretty soon the connector was smoking. It got pretty damn hot. Not so hot I couldn't touch the wires right next to it, but it was hot.

So of course because of the melted connector this had gone on for at least a little while. I have no idea why, other than maybe the R/R or stator is messed up, but that's what's happening.

Any ideas where each of those wires connects? Does it matter?

Why is it smoking? Thanks!

[ghandi1616]

All three yellow wires are work togethor, so they cannot be mixed up. As far as the smoking/melting problem?? It could be an over charging situation, causing the melt down.

[Hordpower]

Pretty common problem on motorcycles, Hondas and Ducatis suffer it the most, it seems. The problem arises when the connectors get corroded over time. This creates resistance in the connection. That's bad. Resistance causes excess heat, the connector melts, sometimes the spades contact each other and that can be pretty spectacular! Even if that stator and regulator live thru the ordeal, then yer kinda screwed because the spade connectors are dirty AND have melted plastic all over them. The solution is to either get a connector kit and re-do the whole thing, or just splice the wires together and seal them with heat shrink.

Anyway, the moral to this excessively long story: Everybody, go out and clean your stator/RR connections right now!

[isaac]

Man that's a relief. That's nothing compared to having to redo the stator. It's still putting out correct voltage so I'm not worried.

[ghandi1616]

I would run out and clean mine right now, but the problem is it is -29 outside. My shed is buried by the blizzard we had yesterday as well.

[NT696]

It happened to me too!!

Freakiest thing. Same situation here. Connector all melted to ratshi*. Everyone should watch out for this one.
I had a spare stator, (with connector) but what is the best way to clean and seal the connectors to prevent it from happening again? Scrape clean with a small tool, dielectric grease, crimp tighter for more friction ,and seal with silicone?
Isaac: does this look familliar?

[isaac]

Re: It happened to me too!!

Isaac: does this look familliar?

Yeah that's it alright. Goo all over, dirty, and broken apart.