Join Date: Jan 2004
Location: Central, Minnesota
Even eliminating the connector and soldering the wires, your still going to have a poor charging system on your bike. The problem is, in my opinion, the voltage regulator and thin stock wiring that causes the problem.
Your stator sends all the power it can to the regulator, thru thin wiring and to a poorly designed regulator that barely keeps the battery charged and causes the wires to over heat. Not only the wires get too hot, but the regulator gets too hot (that's how it designed to work by sending the extra power to ground making it run hot) and keeps the stator running way too hot also.
So replacing the regulator with an after market (Mosfet style) regulator and the stock wiring with thicker 10 gauge wire, will keep things running cooler and keep the battery fully charged, even at idle.
I've recently done this mod to mine after years of poorly charged batteries and it works a **** of alot better than it ever did. My bike charges better at idle now than it used to at full throttle. The bike actually runs better too. I can run my driving lights and stereo and still get 13.5 volts at the battery at idle, and up to 14.2-14.5 at higher RPMs.
I'v never had those kinds of readings all the time I've owned this bike.