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Discussion Starter #1 (Edited)
On my way home this evening my bike started to bogg down and started running like crap. after getting it home I noticed that the headlight was not turning on and the battery was dead. I charged the battery and the bike fired up and ran fine, but the headlight still was not coming on. I found a wiring harness that slipped down and was against the goats belly and was melted. I assume this is the route of my problem after reading through the versus.

would anyone happen to have any ideas of the best way to fix this ?

pictures of the wires are here:
http://www.flickr.com/photos/[email protected]/?saved=1
 

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Premium Member
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369 Posts
At least you have to get new connectors and contacts, you can get them here: http://www.electrosport.com/products/accessories-connectors-wiring.php

Cut the burned part of the wires away and crimp new contacts. If you are lucky, this is all you have to do. If not so lucky, your stator and/or R/R have also fried and you have a more expensive repair ahead.

Looks like your R/R is not original - the original has the connector integrated to the body of the R/R (AFAIK).
 

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I'm not sure if that's heat melting or acid from a wet battery. You might also want to consider switching to a maintenance free battery. There are a number of posts about on that topic.
 

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McGyver
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I always use solder and heat shrink tubing.
I will never trust a crimp on connector, I have seen these things pull apart or rot away many times.
On the other hand it depends on the connectors you use and how You crimp them,
After crimping them on you can hit them all with a little solder to hold them better and insur a good connection..
Just my 2 cents
Safe riding all.
 
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