Replacing the voltage regulator on a 97 F3, noticed the male plug has a tab that is fried. Is there somewhere that sells a new replacement/ repair plugthat I can splice in? ...or am I going to be forced to find a used wiring harness and cut and splice that way? Any insightor suggestions are appreicated.

 

Most people just cut it and run a suzuki gsxr r/r instead...if you choose to replace it with a stock like reg, like i did, get one of the aftermarket ones with the cooling fins on it. The plastic is melted, or the metal prong inside is melted? The metal can probably be found anywhere, ie lowes, home depot....the plastic plug can be found online somwhere..there was a thread a few weeks ago with a link to a whole bunch of plastic plugs

 

or you could solder it and eliminate the plug all together. I just did the gsxr r/r and from what I found people say the harness is part of the problem *ie creating more resistance*...just food for thought.

Dave

 

Here is the site that rez was talking about (electrical terminals and connectors)

 

Thanks for the link and comments. I decided to run with a updated Honda regulator (supposedly it has fins)since I got indecisive with the various aftermarket offerings and mixed reviews about them, and I didn't (originally) want to got through the splice and soldering for a gixxer regulator. ...all of which before I noticed that the plug itself was pretty crispy. Guess I'm splicing and soldering now anyway.

 

Parts Unlimited sells a r/r plug kit for 10 bucks.Parts include metal harness connectors and bigplastic clip.

 

I forgot to mention to check the stator plug under the tank too. When the r/r goes out, it can damages the connections in the charging system.

 

marc0011, thanks for the tip. I'll check that too.

 

No problem. I had the same issue that you have. When my r/r went out, it took the r/r and stator plugs with it.

 

Guys!

The most likely the cause of melted voltage regulator / rectifier connections is not from heat from the actual unit, but from corrosion inside the connection itself.

The terminals oxidize and corrode over time and start to draw more resistance as the corrosion gets worse.

Eventually the resistance gets so hot it melts the connection thus frying the stator and VR.

Honda are notorious for the stator connector melting at the main wire harness and frying the VR and stator.

I would almost bet money Honda a fix kit for the F3 VR connection.

It’s simple OEM male and female connections with a pig tail of wires on each end that matches the F3’s harness, along with soldier and shrink tubing.

I have seen these kits for older Honda Goldwing’s, VFR’s and CB’s.

Honda does not advertise this fix kits because they are trying to avoid a recall so you have to inquire about the fix kit or do a search at Service Honda.

You can avoid this electrical failure by cleaning the connection with electrical contact cleaner and using die electric grease on the connection!