Unreal.. I wouldn't think that turn signal bulbs could draw so much to make a difference, but I'm glad your bike is liking it. I wonder if a set of flush mount led light would be a better mod since they draw less than the stockers...

 

I have thought about changing to led flush mounts. The bulbs might be pulling just enough to effect an aging electrical system. Changing to led doesn't change the fact that the electrical system is old and will need repair but where to start is a big question. All the parts are NOT cheap.

 

Well, I found one of my culprits for my charging system. My stator connector fused/melted. Even the plastic on the wires melted. See picture below. I replaced the wiring and the connector with a better one. Bike is up and running again, but still not 100%. Still has a slight stutter, so I'm pretty much back to where I started. It's not falling on it's face, just sounds like it has a slight miss. Which might be carbs running off too. I need to pull my spark plugs and see if I'm running to rich or too lean. I'm getting horrible gas mileage too. Around 100-120 miles per tank. I used to get around 160.

 

That's pretty melted, I wonder what caused that to happen.

 

Old wires, new regulator/rectifier pulling more current. So far no problems after replacing the connector and all the wires from the connector to the R/R. Still has a slight stutter, but I think that's mainly the carbs. Doesn't change much when the fan kicks on or whatever.

 

^ For clarification to readers, fixed it for you.

Also, since you just found the damaged wires/connections, its likely possible that it was caused before the new R/R installation.

 

It's possible it could have been caused before the new R/R was installed. I'm still having a slight stuttor when at idle. Not sure if it's power related or the carbs not being tuned well enough or out of sync. I will keep you guys updated.

 

I cleaned and applied dielectric grease to a bunch of connections yesterday. Started the bike and all was fine till the fan kicked on. I am thinking maybe the stator can't handle all the load. According to the trouble shooting article I mentioned above, my charging system is "ok". When the bike starts stuttering increasing rpm's gets rid of it but that would mean I would have to keep my bike at around 2k rpm's.

 

Bike has been running great and it is hotter then hell outside. I hope you all figure it out.

 

BiggMatt, you went to LED signals? 2 wire I assume since they are only on when you put on your signals, not as running lights?