Hot stator wires

I can see your problem from both sides. I work in a honda service dept. (cars) and I see all kinds of wacky stuff. You would be surprised how many problems are created by the customers and aftermarket parts. I'm not saying products like the VFRness are no good, but it doesn't surprise me that the dealer would be leery of non-honda repairs.
Is your problem the heating wires, or does the bike not charge?
I do all my own bike work and I moonlight at a cycle shop at night. I have seen some wacky charging issues with these bikes, but never one that I couldn't fix. Are you sure your battery is ok? I was told by an field engineer that most of these reg problems result from excessive resitance in the charging system circuit or poor ballasting by the battery. My '01 charges well, but the reg and wires do get hot. The reg is usually too hot to touch after I get home from a ride. I do keep the bike on a charger when it's parked, but not all the time.
I'm sure there are lots of ideas out there about the r/r issues, but I would stick with the basics. All connections clean and tight, all ground and power connections tight, good battery (should be able to start the bike after leaving the lights on for 1/2 hr) etc,etc...
Good luck

 

Yes, I realize I shouldn't be so critical of the dealership mechanics....I just lost my cool...have been dealing with this problem for several months now, and my frustration got the better of me.

I do understand that I might have created the issue myself by plugging in all those after-market parts, and that the mechanic at the dealership probably has to go back to ground zero in order to figure out why the stator wires get hot enough to burn you (this can't be normal).

After I thought about it a while, I talked to the service manager and discussed his plan to resolve the problem. His next step is to replace the after-market stator with a factory part. I'll keep my fingers crossed.

On a happier note, my other 5th gen seems fine now that I did replace the after-market R/R with the up-graded factory version. I do have the vfrness in place plus an additional ground from the battery to the frame. Also checked/cleaned all connectors that were easy to access.

Jon

 

Because the gear driven 5g is far superior to the VTEC 6g in all respects, it was deemed unnecessary. :biggrin:

 

Ihad the same problem with my 99. A local bike shop told me to sauder the wire's together(at the connections) so I did it, that was over a year agne tip I can provide is to keep track of your wires.

 

The problem bike is back from the shop. They replaced the after-market parts with a Honda up-graded R/R and a Honda stator. The VFRness remains in place. I checked out the wires this morning--they do get warm, but, even after running it a 5K RPM's for a while, the wires do not get hot any more. The charging voltages at the battery are also normal. I am curious why these highly recommended after-market parts, which apparently work fine on other 5th gen VFR's, did not work right on my bikes. This was an expensive lesson in electrical systems.

Jon

 

Great news.

 

I'm glad all is well with your 5th gen!!
Now time to ride!