Melting Wires/Connector PLEASE HELP

[kong2412]

I am going insane regarding a prob with either the rectifier or alternator on my 1995 blade RRS. The connector that contains the 3 yellow wires from the Rec and the 3 yellow wires from the alternator keep frying!!! I have had the connectors replaced the other day and the mechanic said the the Rec woz ok, the battery woz ok and he checked the alternator. Then today I smell burning from under seat after a 3 miles 140mph blast and the connector is melting again!!! I caught it early though as the wires that are from the alternator side look to be starting first?! Where as b4 I just had a mass of black melted plastic and smoky seat.

This leads me to believe maybe the alternator is pumping out too much? There is currently no burning signs on the Rec side of the connector.

I keep battery on an optimate and it keeps fluctuating from desulfate to weak and only once have I had a ok reading in the past 5 days. He tested the battery and said that it was a good as a new one.

I think it had an alarm on and previous owner took off as seems to be a few taped up wires. Any ideas please!

[Brent]

How about an intermitent issues with the rectifier? or the battery or alternator.

Here on this Board Big Kahuna just dealt with a problem like this..

I just cannot find the thread..

[Calkidd]

It sounds like your Rectifier (AKA Regulator) is not regulating the voltage as it should. If you don't get the problem fixed not only will you need to replace your Rectifier you will have to replace your Stator at about $180.

Here it how to test the rectifier.....

1. Take the plug (under the seat) that leads up from the stator and unplug it.

2.Take a VOM meter and put the red lead into one of the plug ends, its doesn't matter which one.

3. Now, take the black lead and touch either the ground on the battery or on the frame.

If you have continuity or the VOM sounds then your stator is bad.

Also you can check for resistance. If you jump from one lead of the plug to another lead, again it doesn't matter which one, you should get .1-.3 ohms. The meter will jump up so give it some time to settle down.

The first test is a dead bang way to find out if your stator is bad.

What can happen, in BK case, the rectifier (AKA regulator) doesn't stop the juice from flowing therefore causing the stator to over charge and burn up.This is what I posted in this thread http://www.rrzone.com/forums/showthread.php?t=1039&page=3&pp=10&highlight=Rectifier

[kong2412]

Ok thanks alot for the advice the mechanic has picked bike up today and I have told him what you say. I will let you know if any progress. Thanks :(

[the spindoctor]

also, if you have aftermarket headlights it can do this too. same thing happened twice on my old gixxer 750.

[akatony]

i went threw the same probs with my 96 check your ground i hade to go threw my harness conecting a new ground in the front and in the back stoped the prob

[kong2412]

mechanic told me that theres a circuit between the yellow wires from the alternator to him sugesting that the diode is shot and I need a new alternator! Is this correct? Summer here in the UK has been total cr*p and its not helping me that when it is sunny I cant use my bike!! Would these problems caws my battery to bite it as is doesnt seem very happy on the optimate trickle charger? Thanks again

[kong2412]

i went threw the same probs with my 96 check your ground i hade to go threw my harness conecting a new ground in the front and in the back stoped the prob

When you say harness do you mean wiring loom for the entire bike? Sorry I arnt very good with electrics, only the guitar type anyway :)