Chewtoy Posted January 7, 2012 Share Posted January 7, 2012 Went to clean the connections on the starter relay and looked @ the R/R. Yikes! Found 1 yellow stator wire burnt and corroded off the plug. Can anyone direct me to what's wrong? And I guess I need (at least) a new plug. Have heard that bartonMD is the source for those. Is that right? Links to pictures: http://twitpic.com/84fk98/full http://twitpic.com/84fg1m/full Quote Link to comment Share on other sites More sharing options...
Chewtoy Posted January 7, 2012 Author Share Posted January 7, 2012 Update: Removed plug from R/R, only the 1 stator plug was affected, others look OK. The burnt yellow wire melted the insulation on one other yellow wire, the red/white and green wires are unaffected. So, for now, it looks like that 1 wire had a bad/weak connection. I need a replacement plug and a bit of solder. Hopefully the stator + R/R are OK. Update 2: I cut away the charred part of the plug, and wired up a short lead to a connector, then connected the wire to the original yellow wire. The other yellow wire that got a bit burned got taped. Hooked up and it looks OK. It's ugly, but will do for now (I think). Anyone w/thoughts, please sing out. Thanks! Quote Link to comment Share on other sites More sharing options...
blackhawkxx Posted January 7, 2012 Share Posted January 7, 2012 Did you test your voltage at the battery with the bike running? Quote Link to comment Share on other sites More sharing options...
Chewtoy Posted January 7, 2012 Author Share Posted January 7, 2012 Did you test your voltage at the battery with the bike running? 14.45 @ 2k Quote Link to comment Share on other sites More sharing options...
blackhawkxx Posted January 8, 2012 Share Posted January 8, 2012 14.45 @ 2k Did it (volts) go higher with more revs or did it stay at 14.45? I would check it up to 5 K just to be sure. Quote Link to comment Share on other sites More sharing options...
Chewtoy Posted January 9, 2012 Author Share Posted January 9, 2012 14.45 @ 2k Did it (volts) go higher with more revs or did it stay at 14.45? I would check it up to 5 K just to be sure. 14.24@3k 14.12@5k Quote Link to comment Share on other sites More sharing options...
Warp11XX Posted January 9, 2012 Share Posted January 9, 2012 Solder and heat shrink. Honda electrics suck from way back when and they still haven't learned anything. Everything else they do makes it worth it.... Quote Link to comment Share on other sites More sharing options...
Chewtoy Posted January 9, 2012 Author Share Posted January 9, 2012 Solder and heat shrink. Honda electrics suck from way back when and they still haven't learned anything. Everything else they do makes it worth it.... Yeah, I'll get some high quality connectors and re-do all the leads this weekend w/solder + Heat shrink. I'm just glad I caught this before the thing caught fire or killed some expen$ive parts. Quote Link to comment Share on other sites More sharing options...
Hobicus Posted January 9, 2012 Share Posted January 9, 2012 Solder and heat shrink. Honda electrics suck from way back when and they still haven't learned anything. Everything else they do makes it worth it.... Yeah, I'll get some high quality connectors and re-do all the leads this weekend w/solder + Heat shrink. I'm just glad I caught this before the thing caught fire or killed some expen$ive parts. I had a similar problem.. rather than leave the connectors there, I did a nice western union splice and soldered/shrink wrapped the whole thing. Been rock solid since. On challenge was the gauge on the wire is pretty thick, so it took some time to get the wires hot enough for the solder to flow. Of course, if I'd had a better soldering iron, that wouldn't have been an issue. My thought was that if it fails, I'll probalby replace the RR/Stator in combination again, so I didn't mind the idea that I might have to cut the wires. Quote Link to comment Share on other sites More sharing options...
Chewtoy Posted January 10, 2012 Author Share Posted January 10, 2012 Solder and heat shrink. Honda electrics suck from way back when and they still haven't learned anything. Everything else they do makes it worth it.... Yeah, I'll get some high quality connectors and re-do all the leads this weekend w/solder + Heat shrink. I'm just glad I caught this before the thing caught fire or killed some expen$ive parts. I had a similar problem.. rather than leave the connectors there, I did a nice western union splice and soldered/shrink wrapped the whole thing. Been rock solid since. On challenge was the gauge on the wire is pretty thick, so it took some time to get the wires hot enough for the solder to flow. Of course, if I'd had a better soldering iron, that wouldn't have been an issue. My thought was that if it fails, I'll probalby replace the RR/Stator in combination again, so I didn't mind the idea that I might have to cut the wires. Very cool. Thanks! Quote Link to comment Share on other sites More sharing options...
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