After taking care of the various issues my bike had this season, I thought i was done.... But i was wrong. One thing that had appeared a few months back was it had died on me while riding. The charging system had not operated and the battery drained completely leaving me stuck on the road. After jumpstarting however, i checked voltage and it was charging just fine. The symtom dissapeared for three months...

Last week I took the bike around town one morning and when I was pulling in a parking lot, I noticed the rpms were unstable. Sensing a issue I decided I should just get it home as I was 2.5 miles from my house and I had to leave for college within an hour. Immediately upon going back on the road, I find the bike hesitating to get above 6k rpms in 3rd. I get about a mile down the road and once i hit a slight incline it completly dies and to my luck i roll straight into my friends driveway. Once again the battery is completely dead. This time after charging the battery overnight, I notice when I restart the bike and give it throttle the charging system is still not working. Before purchasing a new stator and voltage regulator i decide to do all the tests and when I trace the wire from my stator to the main harness, I find this: (image below)

The connection module on the stator wire looks as it it had been completely melted. After cleaning the 3 metal prongs, I reconnect the wire and the charging system is working great. giving me a 14.5 volt charge at 6k rpms. To my despair, I found that no one sells this connection wire sepeate as it is attached to the stator. After rechecking the connection i found it was very hot, likely from all the resistance being created. Does anyone know of a place were I could purchase just a new wire module??? I figure I could use a heavier gauge wire and splice and wrap all the connections. Anyone have any ideas or suggestions??

[IMG]local://upfiles/18268/065471DDDE04417C9A1D9989ABDF9EF1.jpg[/IMG]

 

I'd get a new battery too. From my experience, after you let the battery completely drain it never holds a charge right anymore.

 

Yea I was thinking about that. Sucks because I just replaced it about 11 months ago, but yea thats probably not a bad idea.

 

I'm not gonna lie. I didn't read your post cause I tipped back a couple of beers. But I wanted to complement you and your front end. ON THE BIKE. The black as opposed to the stock orange like mine. I think I may copy you. Looks cool!

 

Thanks. I think i posted some other shots in the picture thread at some point. I like the way the black fron fairing looks against the orange tank and wheel guard

 

what sucks about this connector is that it's right next to the rear suspension constantly getting doused with water in the rain. I keep mine wrapped up in electric tape.