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  • Wires too hot

    I have a new problem, and i feel like some extra background is needed.

    I got the bike last year, it was in a barn for years after the owner died. The wife of the owner finally decided to get rid of it. The person that got it, did some work and then i got it from them. I just went had a problem with it not starting, but after cleaning some contacts, and fuses, it is now starting.

    as it was running and i was starting to put the covers back on the fuse box area i noticed a little smoke coming from the wires by the battery. So i turned it off and continued to look. The wires were too hot to touch and were taped together and kind of zip tied to the connector. I am not sure where these 3 wires go, the connector that it looks like they fit into (but were not in) disappears down the middle of the bike and under. It was too hot to see where it ends yet.

    the 3 wires were taped together at the end, so i dont think they were hooked in, but cant say.

    and finally, I took them all apart, and started the bike and it ran and all lights worked. I am not sure what is not working, but reaching out for any assistance that can be provided.


  • #2
    Those look like the three wires from the stator. Stator puts out alternating current to the rectifier/regulator that changes it to DC voltage for the electrical system.

    Bad connections will increase resistance to pass current and melt wires quickly.

    Comment


    • #3
      The male plug with the three white wires goes to the stator, the female to the regulator/rectifier. The plug in your picture looks like the male plug. I don't know why it would get hot unless some of the wires are melted together and they do look a little bubbled.
      Scott B.

      Comment


      • #4
        They were all taped together, so I am sure they were touching each other. And yes they are bubbled/partially melted even. Not sure why they were not plugged in right.

        i feel like they were supposed to be in a clip but at some point the clip broke or something, and they had it stuffed in place and when i started working on my other problems, i may have moved them and caused them to cross.

        Can i just clean them up and plug them in to that connector? How do i know which one goes in which spot?

        thanks for the input.

        Comment


        • #5
          Also as I think about it, the battery is only good for about 5 starts before i need to jump.
          this is not normally a problem as i only ride with a few stops and then it is in the garage and i plug in the tender.

          could that be affecting the charging system?

          Comment


          • #6
            Wow, after just a little looking, i realize how bad that questions was.

            Comment


            • #7
              The white wires can plug together in any order. However, I think you're looking at a new stator and regulator plus new wiring from the bare pins to the regulator unless you can determine those wires are in good shape.
              Scott B.

              Comment


              • #8
                “... unless you can determine those wires are in good shape.”

                Checking the AC voltage from the stator and DC voltage from the regulator to the battery would be up there on my list of things to do, as well.

                Comment


                • #9
                  Ok, so here is the next step in this process.
                  I am learning a lot here, let me say thank you all.

                  So i bought a new Stator and regulator/rectifier and set out to get the old one out.

                  i was able to get everything apart and was surprised to see the stator and inner area was covered in oil.

                  Is this normal?
                  Can i just clean this all up, and put in the new one? Or is there something else i need to look into.

                  Comment


                  • #10
                    It is normal for oil to be in that area. After replacing the stater make sure you have good clean gasket surfaces and gasket. Oil pressure goes through one of those ports.
                    While your in there, you might check the torque on the hub, making sure that bolt is tight. On the 1999 thru 2003 models, they can work loose causing starter spin. Meaning the tapered shaft to the hub spins and not locked together.

                    Comment


                    • #11
                      Didnypu buy OEM stator and regulator? If you got aftermarket you will likely be replacing them in a few months.

                      Comment


                      • #12
                        Hmmm, I did not buy OEM they were from eBay. I will keep that in mind in a couple months if i see the same problem. I know a lot more now about how to test them, so at least i wont have to go though as much trouble shoot and not knowing.

                        Comment


                        • Duke
                          Duke commented
                          Editing a comment
                          Your old stater pictured looks good, windings not showing any brown. You can check them out with a ohm meter.

                      • #13
                        While i was putting this all back together, I noticed a wire that comes off the right side of the engine thru the frame by or toward the fuse box. But is broke. I need some help identifying,

                        the little black wire in the middle of the picture.

                        Comment


                        • #14
                          That wire is the neutral sending wire, it grounds out when the transmission is in neutral.

                          Comment


                          • #15
                            So with that wire, it is not attached to anything, does that mean that it does not need to be in Neutral to start, or that. It wont recognize that it is in neutral?

                            Comment


                            • Duke
                              Duke commented
                              Editing a comment
                              If it's not grounded out, then to start it, you would have to have kick stand up and the clutch in, then it would start.

                          • #16

                            Comment


                            • #17
                              I found a wire connector that was the same color and connector to plug that into.

                              i got it all back together, and working. Feeling pretty good right now.

                              thanks all for the help.

                              Comment


                              • #18
                                This was a great thread to read but if were having these issues with a bike I would be so f’d even with all this great advice...I thought an ohm meter was something you used to check if your girlfriend was ovulating...I’ll let myself out...zing goodwrench...

                                Comment


                                • Duke
                                  Duke commented
                                  Editing a comment
                                  We were talking electric, not temperatures! LOL!

                                • zingpow
                                  zingpow commented
                                  Editing a comment
                                  duke...i have the worst kind of mechanical dyslexia, i can read mechanical cures word for word (with pics and video) and not understand a bit of it...it may as well be written in french...i have tools and shortened fingers with no feeling in the tips to prove it...zing goodwrench...

                                  ps...i still read these threads hoping that one day the light will come on...zing braille...

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