I recently replaced the rectifier in my 91 1000f. I usually do not bring my rpm's over 8K but I was pushing the bike a little harder the other night and it all shut down. The rectifier was smoldering and the main fuse popped. After it cooled a bit, I put in a spare 20 fuse(needs a 30), just to see if I could make it home and it popped.
Does anyone have an idea what is up. I bought the rectifier just a month ago. It was hot and smoking when I took the seat off.


Help!!!!

 

It almost sounds like you have a bad grounding (or shortening) on the bike which can kill a new R/R in a fraction of a second when current flows wird routes. Check the grounding on battery minus and its grounding to the frame. There is also a posted thread in this forum which give good hints for better survival due to bad cooling of the R/R. The most important thing is to have metal-to-metal contact between the R/R and frame, that will dissipate the R/R heat real good. The ground wire on the R/R mounting screw, and the threads in the frame can corrode and needs to be cleaned as a preventive action. Such quick failures like yours, especially in the night, points more to a connection problem. Also check that your battery is fresh before putting in an new R/R.

 

Did you buy an Electrosport regulator / rectifier?? I did and it ran too hot for my tastes so I bought a Rick's Electrics unit and modded a heatsink onto it. But yeah, sound like something is shorting the main fuse, especially it it pops right away.