During this past Spring, during the initial start-up of this bike, the battery was completely dead; necessitating a jump start from a lawn tractor's battery. While the engine was being revved in place to charge up the motorcycle battery, smoke started rising up from the battery compartment area until the bike engine suddenly died. Thereafter, no instrument lights on the speedometer were illuminated.
Fast forward to one week ago. I observed a melted/burned white plastic connector where the alternator stator's three yellow wires connect to the motorcycle wiring harnesss. In addition, the 30 amp main fuse (located immediately above the battery) was blown.
To repair the three yellow wires, I cut away the remains of the white plastic connector plug to expose the brass spade-type wire terminations. Any burned plastic on the brass wire terminations was scraped off with a razor blade and cleaned with electrical contact cleaner. Care was exercised to not mix up the wire connections on the AC voltage just in case...
A section of heat-shrink tubing was placed over each of the three yellow wires. The spade terminals were fluxed, connected and soldered together then the tubing was shrunk over each respective. I stuffed the newly repaired connectors into the clip which formerly secured the white plastic plug and zip-tied it in place.
PS This motorcycle had previously sustained a failed alternator. The local Honda dealer installed an aftermarket stator to restore alternator output.
Fast forward to one week ago. I observed a melted/burned white plastic connector where the alternator stator's three yellow wires connect to the motorcycle wiring harnesss. In addition, the 30 amp main fuse (located immediately above the battery) was blown.
To repair the three yellow wires, I cut away the remains of the white plastic connector plug to expose the brass spade-type wire terminations. Any burned plastic on the brass wire terminations was scraped off with a razor blade and cleaned with electrical contact cleaner. Care was exercised to not mix up the wire connections on the AC voltage just in case...
A section of heat-shrink tubing was placed over each of the three yellow wires. The spade terminals were fluxed, connected and soldered together then the tubing was shrunk over each respective. I stuffed the newly repaired connectors into the clip which formerly secured the white plastic plug and zip-tied it in place.
PS This motorcycle had previously sustained a failed alternator. The local Honda dealer installed an aftermarket stator to restore alternator output.
