My question is the yellow wires that run to the regulator all got hot and I was wondering if I should replace all the wires from the first plug by the battery all the way to the regulator and solder all of the connections.
Yes the plug by the battery was long ago changed to soldered connections. I was thinking that I might want to cut them out and run all new wires all the way to the regulator and then hard wire the voltage regulator in thus eliminating the melted male part of the regulator plug. (Or can I get a replacement plug for the wire harness)
just me but i soldered all those wires[ using existing wire ] and did away with plug all together, be sure you have clean wire, can dip in baking soda and water mix or as someone posted clr then rinse with clear water, dry then solder, flux can help for good connection. good luck:action::waving:
What started my charging system rebuild was she blew the 30 amp main fuse.
she would not hold her 30 amp fuse (key on or off) till I found the 2 touching yellow wires and the burnt plug at the regulator/rectifier separated them and removed the regulator.
The test showed that at least 2 of the diodes were gone as it would pass voltage both ways (red to green and green to red) 0.000000 resistance.
I would assume that it was caused by a bad connection that got hot in that plug. As when I got the melted plug apart the contacts were black and burnt for one of the yellow wires and that wire was welded to one of the other yellow wires. (dead short)
she started and ran on battery several times without the regulator to do the stator test and drive herself home from the store.
Is there a test that will tell me if my bike has excessive voltage/amperage draw?