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| xs650 > > Motorcycle Systems > > Electrical > > Meltdown, ever see this? |
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Blackbird
Full Member
Joined: May 13, 2009
Posts: 20
Location: Detroit
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 Posted: June 21, 2009, 10:00 am Post subject: Meltdown, ever see this? |
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My 1980 XS has a slight problem. The connector from the stator has melted a bit. Needless to say it does not charge. I jumpered the middle white wire, that you see is cut, in hopes it would charge. No Go. Any thoughts on why this happened?
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Retiredgentleman
650Rider Supporter
Joined: Mar 03, 2007
Posts: 2258
Location: Calgary, Alberta 1978 XS650 SE
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| Posted: June 21, 2009, 11:58 am Post subject: Re: Meltdown, ever see this? |
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There are several reasons that the connector over heated.
A short circuit may have occured causing a high current flow. Does the bike have its normal 4 fuses and are they the correct amp rating?
The rectifier/regulator may have a fault. The rectifier portion can be tested with an ohmmeter ( diodes have high resistance one way and low resistance the other way when not faulty). Testing explained in a Haynes Manual or Yamaha service manual.
Another possibility is that the connector pins simply got dirty/oxidized/corroded over the years. This causes the resistance to increase and heat builds up, melting the plastic.
You can buy replacement connectors from mikexs, to redo the wiring. That may be all that's required. It would be wise to do some testing.
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Blackbird
Full Member
Joined: May 13, 2009
Posts: 20
Location: Detroit
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| Posted: June 23, 2009, 9:25 am Post subject: Re: Meltdown, ever see this? |
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| Retiredgentleman wrote: |
There are several reasons that the connector over heated.
A short circuit may have occured causing a high current flow. Does the bike have its normal 4 fuses and are they the correct amp rating?
The rectifier/regulator may have a fault. The rectifier portion can be tested with an ohmmeter ( diodes have high resistance one way and low resistance the other way when not faulty). Testing explained in a Haynes Manual or Yamaha service manual.
Another possibility is that the connector pins simply got dirty/oxidized/corroded over the years. This causes the resistance to increase and heat builds up, melting the plastic.
You can buy replacement connectors from mikexs, to redo the wiring. That may be all that's required. It would be wise to do some testing. |
This bike does have it's normal fuses and they are the correct amp rating.
I'll test the best I can and see what happens. Thanks for your input!
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Blackbird
Full Member
Joined: May 13, 2009
Posts: 20
Location: Detroit
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| Posted: June 28, 2009, 8:48 pm Post subject: Re: Meltdown, ever see this? |
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| Well ... I got lucky. I rewired using bullet connectors and the system is now charging. Keeping my fingers crossed.
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