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Discussion Starter #1
hi all, just started the bike right now and was going for a quick spin in the neighborhood, when i looked down and noticed smoke coming from my stator wire connecters. the bike was running maybe 3 minutes when i noticed. the bullet connector covering was blistering and it melted the tie that it was in by the frame distal from the stator. HELP!!!!!!!!!!
some added notes to this situation i find myself in is;
1) the wires are distal to the stator's connections, they are a smaller gauge wire and thes are the hot ones. the wires from the stator seem warm & i think mostly from engine heat.

2) i did a voltage check and at idle its 12.57 volts and at 3,000 rpm its 14.56 volts.

3) the rectifier gets warm real quick idling, parked ( it's relocated by foot peg)
another thing i did about 2 weeks ago with all my electrical conections was clean them with contact cleaner and used di-electric grease in all the connections i started the bike before and the wires are hot but no smoking or melting was noticed by the connecters ran bike for 10 minutes

could this be a rectifier going bad problem? Thanks for any help you can give me

ride safe john
 

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Search Goddess
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By chance did you bundle your stator wires together? Don't! Or if you do, wire tie them LOOSELY. The stator wires do get warm.. very warm and need air curculation. I had a similar meltdown and resulting fire when my stator wires were tucked back against the frame and wire-tied to neaten thing up. The insulation melted and they shorted and started the fire. Yours is the third I have heard of and in the other 2 cases (mine and one other) we had bundled the wires together
 

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If the connectors got that hot, you will need to replace them or you may just want to cut them out and solder the wires together. Also, as Dianna said, dont bundle them tightly.
 

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Dianna said:
..... The insulation melted and they shorted and started the fire. Yours is the third I have heard of and in the other 2 cases (mine and one other) we had bundled the wires together
ohhh.... that is bad. they should use a larger gauge wire there or a solid wire. good thing no one got hurt. shouldnt there be a recall on that?
 

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Discussion Starter #5
yes Dianna & Loran,

that is what i did (bundle them together), wanting to clean it up under the seat. glad i noticed otherwise would have been a short riding season that went down in flames.

from the yahoo group and the latest repeat thread on "fusing stator wires", i went out and bought fuse holders and fuses for that project to do when i felt like it. guess i better feel like it real quick. Loran the connectors are toast so this weekend i'll solder in the fuses and shrink wrap the connections where the connectors meet and i will put spiral plastic wire guards on each wire. i figure if i stretch the guards air will get to the wires for cooling and there is no way for the wires to come in contact with each other. i'll also tie them to the frame by themselves.

once again thanks for all you're help. hope to get to a "gathering" and thank you all in the flesh.

ride safe john
 

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Search Goddess
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Hizzo, no need for a recall. It does not happen when the wires are left as installed. It only happens when the owner bundles them together and the collective heat melts the insulation.
John, I don't know if I would put the spiral wire guard on the wires either. These wires want/need air. I did wire tie mine again but kept the loop holding them large, about a half dollar size so they could still move but were "guided" back out of the way.
 

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hearing this though makes me wanna do my own rewind on a stator just so i can use better wires and not over heat....
 

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This problem is common on other bikes as well. I had to do it on one of my Honda V65 Magnas last weekend. On that bike, the wires have a single rectangular connector to melt. I just wished I could have found some yellow heat shrink locally because that would have looked better than the black.
 

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Search Goddess
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Hizzo, Just to clarify, it is the three wires coming 'from' the stator that overheat when bundled. With the stator itself the eventual demise is the insulation breaking down (Ok, that is heat related too but takes a lot longer)
One thing I would do is throughly inspect any stator to make sure the coating is uniform over the windings. A couple of members in the yahoo group have picked up bad stators to rewind but no bike installed reports yet.
 
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