I installed a Yamaha R1 rectifier on my 1994 VFR years ago however that did not prevent the poor wiring layout from the stator to the rectifier from melting this week. I am going to run heavy gauge wire direct from the stator to the RR with no connectors (if I needs to be cut it in the future to service work so be it). I am also running a heavy gauge ground to the battery negative terminal and a 30 amp fused heavy gauge wire from the positive battery terminal to the RR. I am the original owner of the VFR and have bought and sold many bikes while owning it but will never sell the VFR. This wiring problem and the rectifier itself is the only issue I have had with the bike, it is a common problem and a design flaw. I have not posted on the board in years but often look at the site. If you want more information on what I am doing send me a message; I am sure this information has been posted many times but given the trouble I have had I figure it does not hurt to offer help should others want it. JIM
All good steps, the 3 pin connector on the stator wires was your culprit, gauge of stators wires is fine. However, Honda chose to use 2 wires/connectors in parallel for the + and the - leads from the R/R back to the battery. Logic says if one connector fails, then entire load transfers to the remaining wire/connector which would not be adequate. I did the same thing on my 6th gen by running a #10 return wire back to battery.
