I'm sure this has been gone over. 98 motor. I thought I did all the preventatives. I have a rewound stator. A MOSFET RR from RM Stator. A YTZ14S battery. *VFRness. Yet, my stator to RR connection is so hot it will melt. It's hot to the touch before the bikes motor is even at 100°f. Also, with nothing additional/aftermarket running. Running voltage is 14.6v. I feel like a ride into higher temps would bring that connection up to melting temps. I'd like to hear other's remedies. The RR isn't even hot. Just the connection is. Although I had just had my first RR failure not too long ago. It was a MOSFET, and I had the Vfrness. So a failure still happens with these. All I did was replace the RR. Now everything works, but that stator to RR connection is super hot. Makes me think a longer ride would melt it.
Heat at a connector is a sign of excessive resistance at that point so nothing to do with the health of the stator or RR. Seems to be an issue for the 5th gen due to the position where it can get road spray which starts a bit of corrosion which increases resistance which causes heat which (eventually) melts the plug body. There's also 50V AC in those wires. The best fix is likely to be cutting the connector out and soldering or crimping wires together with heatshrink as needed. I did that on my last 5th gen and the wires were only ever slightly warm after that.
I was afraid that was the solution. Not too big a deal. There's plenty of wire to work with. The RM Stator MOSFET RR has a long lead. I'll do this and update. Thank you.