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Join Date: Nov 2007
Location: Chandler, Arizona
Heat, in ANY electrical circuit, comes from resistance. Resistance is like to much pressure in a water hose. If it gets to high, the hose will blow. Wires will get hot, and if the resistance goes high enough, they will catch fire and burn into. If the stator was generating power into a dead short, then the wires would get hot. I have found those three yellow wires get hot anyway. Very possible the R/R does not have the capacity to handle the stators output, or is borderline, and if the resistance goes up any more, something will burn. I'm still not sure how the Vulcan is wired. It's possible that a shorted battery could cause high resistance, but it shouldn't. That is such a common problem the charging system should be protected against it. If there were no output from the stator there would be no reason for the yellow wires to get hot. Also, you cannot check the stator output without a good battery that is fully charged. My battery was also dead. I disconnected it, and connected a jump start booster pack to the bike cables. It started and ran fine. But I got no voltage increase at all even revving it up to 3000 rpm.
I have found a LOT of electrical systems where serious $$$$ damage could be done by high resistance or reverse polarity. Nothing was done to protect these expensive parts, though it would have been easy to do so. Hooking up jumper cables backwards can destroy the main ECM in a newer car. Manufacturers love to sell expensive parts.
I am a motorcyclist, NOT a biker.
1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike