Replaced my original R/R on my 87 VFR700 last summer, at about 20k. Was at my friend's house a few days ago, and she wouldn't start when I was about to leave. No big deal, must be another faulty R/R again, drift-started her and rode on home. On the ride home I was thinking, "I remember replacing that old R/R with a newer one from a ZX1100 I believe, with a MOSFET setup that is much more reliable that the SCR setup." Pulled the R/R off the bike and one of the wires coming from the stator is melted and the connection broken. What causes this? I would think there would be a fuse to prevent excess current from going through the wiring harness before the wires melt. Any advice would be AWESOME! -Klos
Hmm, that looks interesting. Is it possible that the wires weren't plugged in tight or something got in there and shorted them? Was there tape around them to seal out crap?
Im with reg... Just looking at the far left plug it looks like their is some metal showing. Wouldnt take much to start a melt like that. Only suggestion is to take the wires off and re-do them but put some other sort of protection on them first like shrink wrap, then tape them if you wish. Just make sure the opening to the splice is covered and protected along with the wire. Hope this helps.
Talked with the old man and that's what he thought of as well. Re-did all the wiring and through some dielectric grease in there then wrapped her up with electrical tape real well. The R/R is putting out between 14.5-15.1 V between idle and 5k without being hooked up to the battery. Thanks a ton guys.
