Burnt Wiring

Stainer · 11-02-2009, 12:59 AM

help wanted.have recently replaced R/R with up grade to wiring.Now the wiring has burnt out at the 3 plug from my R/R to my coil/stator.so i have looked for any loose connections and can not find anything wrong.Also do the three yellow wires that come from the coil have to plug in a certain order or do they just go into anyone of the other 3 yellows that come out of the R/R.Because I dont no which is which now.hence the burning.

Tighe · 11-05-2009, 08:26 AM

I have the exact same problem. The wires are not marked and the wiring diagram is not clear on this.

Tighe · 11-05-2009, 06:46 PM

Regulator/Rectifier

TOE CUTTER · 11-05-2009, 06:52 PM

The order of the yellow wires does not matter.They all throw the same A/C current to the R/R. The wires tend to be damaged past the plug and repairing the damaged wires and connections will bring the resistance down and heat .

GoForARide · 11-05-2009, 07:32 PM

im not an expert at all, but it seems if you did not have a problem, changed the rr, now you have a problem. coudl be a faulty rr

NorcalBoy · 11-05-2009, 10:23 PM

my take on this whole thing is that a certain japanese metallurgist monkey'd the actual plug pin materials and they have a relatively high resistance...which leads to the heat failures of the electronic circuitry. that and water and condensation over time, can eat up susbstandard quality wire.

Stainer · 11-06-2009, 04:37 AM

thank you every one.I tend to agree with you all the wiring on these bike are not to good at all.but i have cut out the old burnt wire and replaced it,so if it happens again its off to the shop.thanks again and safe riding.regards Troy

dizzy · 11-06-2009, 06:20 AM

Having seen this many, many times on GL1200's (different bike, similar charging system), the thing I most commonly found was that either the bike was ridden with a chronically weak battery, or ridden with a good battery that was discharged. That 'plug' melting can happen on that one occasion you jump your bike to get it started, then go down the road thinking your charging system will charge your battery.

Your regulator is constantly trying to keep your battery at the proper DCV, shunting current away, or directing it to the battery. If you put an ammeter on your battery cable, start your bike and go for a ride...you'd see a spike in charging initially, to replace the capacity in your battery lost from running your starter. But once the system stabilizes and you're riding down the road, A good fully charged battery might draw as little as just a few amps, while a discharged or weak battery might draw as much twenty amps or more to maintain the regs target VDC.

Anybody that works with electrical generators knows that more load equals more heat, and heat IS the enemy of wires and components. While a poor connection on that three pin connector is enough to do some 'arc weldin' inside. I tend to think that just as often the culprit is weak or discharged battery.

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11-02-2009, 12:59 AM	#1 (permalink)
Stainer Junior Member Join Date: Aug 2009 Last Online: 11-07-2009 04:49 AM Location: Perth West Australia My Ride: GEN 5 VFR800,98 Posts: 12 Thanks: 0 Thanked 0 Times in 0 Posts	Burnt Wiring help wanted.have recently replaced R/R with up grade to wiring.Now the wiring has burnt out at the 3 plug from my R/R to my coil/stator.so i have looked for any loose connections and can not find anything wrong.Also do the three yellow wires that come from the coil have to plug in a certain order or do they just go into anyone of the other 3 yellows that come out of the R/R.Because I dont no which is which now.hence the burning.

11-05-2009, 06:52 PM	#4 (permalink)
TOE CUTTER Banned Join Date: Nov 2008 Last Online: Yesterday 09:47 PM Location: Sacramento - Find Me! My Ride: 2007 RWB 1990 RED 1986 750 DRZ 400 View my Photo Gallery Posts: 1,338 Thanks: 75 Thanked 120 Times in 108 Posts	The order of the yellow wires does not matter.They all throw the same A/C current to the R/R. The wires tend to be damaged past the plug and repairing the damaged wires and connections will bring the resistance down and heat . __________________ Government exists to protect us from each other. Where government has gone beyond its limits is in deciding to protect us from ourselves. Ronald Reagan

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11-05-2009, 08:26 AM	#2 (permalink)
Tighe Member Join Date: Dec 2008 Last Online: Yesterday 08:46 PM Location: Sacramento My Ride: 1986 VFR750 View my Photo Gallery Posts: 59 Thanks: 18 Thanked 0 Times in 0 Posts	I have the exact same problem. The wires are not marked and the wiring diagram is not clear on this.

11-05-2009, 06:46 PM	#3 (permalink)
Tighe Member Join Date: Dec 2008 Last Online: Yesterday 08:46 PM Location: Sacramento My Ride: 1986 VFR750 View my Photo Gallery Posts: 59 Thanks: 18 Thanked 0 Times in 0 Posts	Regulator/Rectifier

11-05-2009, 07:32 PM	#5 (permalink)
GoForARide Senior Member Join Date: Feb 2009 Last Online: 11-19-2009 07:09 PM View my Photo Gallery Posts: 511 Thanks: 4 Thanked 12 Times in 11 Posts	im not an expert at all, but it seems if you did not have a problem, changed the rr, now you have a problem. coudl be a faulty rr

11-05-2009, 10:23 PM	#6 (permalink)
NorcalBoy Uber Guru Join Date: Aug 2007 Last Online: Yesterday 05:51 PM Location: Earth - Find Me! My Ride: Is White View my Photo Gallery Posts: 2,067 Thanks: 43 Thanked 268 Times in 207 Posts	my take on this whole thing is that a certain japanese metallurgist monkey'd the actual plug pin materials and they have a relatively high resistance...which leads to the heat failures of the electronic circuitry. that and water and condensation over time, can eat up susbstandard quality wire.

11-06-2009, 04:37 AM	#7 (permalink)
Stainer Junior Member Join Date: Aug 2009 Last Online: 11-07-2009 04:49 AM Location: Perth West Australia My Ride: GEN 5 VFR800,98 Posts: 12 Thanks: 0 Thanked 0 Times in 0 Posts	thank you every one.I tend to agree with you all the wiring on these bike are not to good at all.but i have cut out the old burnt wire and replaced it,so if it happens again its off to the shop.thanks again and safe riding.regards Troy

11-06-2009, 06:20 AM	#8 (permalink)
dizzy Senior Member Join Date: Apr 2008 Last Online: Yesterday 05:15 PM Location: MN My Ride: 07 VFR800 93 ST1100 Posts: 262 Thanks: 4 Thanked 28 Times in 24 Posts	Having seen this many, many times on GL1200's (different bike, similar charging system), the thing I most commonly found was that either the bike was ridden with a chronically weak battery, or ridden with a good battery that was discharged. That 'plug' melting can happen on that one occasion you jump your bike to get it started, then go down the road thinking your charging system will charge your battery. Your regulator is constantly trying to keep your battery at the proper DCV, shunting current away, or directing it to the battery. If you put an ammeter on your battery cable, start your bike and go for a ride...you'd see a spike in charging initially, to replace the capacity in your battery lost from running your starter. But once the system stabilizes and you're riding down the road, A good fully charged battery might draw as little as just a few amps, while a discharged or weak battery might draw as much twenty amps or more to maintain the regs target VDC. Anybody that works with electrical generators knows that more load equals more heat, and heat IS the enemy of wires and components. While a poor connection on that three pin connector is enough to do some 'arc weldin' inside. I tend to think that just as often the culprit is weak or discharged battery.