Charging Wire in Headlight

[Guest]

I have read the stator papers to understand why the molex connector in the headlight bucket melts but I don't see what the fix is. I have searched for the fix and cannot find anything. I thought there would have been a step by step how-to fix for this with pictures and it stickied.

Can anyone tell me what I need to do to fix this and what I need to do with the unused wires? I cut the melted connector off and was planning to just use plug connectors on the wires.

Thanks for the help

[tom203]

What bike/year are you talking about? hint- put in your signature
A connector melts because it's carrying too much current, or it's very corroded and acting like a resistor. Which connector are you refering to- what are the wire colors? Do you have stock headlight setup?

[old_skool]

I can't think of any wires regarding the charging system that makes its way all the way up to the headlight bucket, even the redundant loop wire usually does its turn around somewhere beneath the tank on a 6 or 9 pin.

[Steve]

As Tom mentioned, the only reason any connector melts is HEAT. The biggest cause of heat is POOR CONNECTION. That is one reason that one of our preaching topics is CLEAN YOUR CONNECTIONS.

Not sure what "unused wires" you are asking about, what colors are involved. Depending on year and model of your bike (HINT, HINT) there might be an extra wire for an accessory or for front running lights, as well as a ground for them.

.

[koolaid_kid]

Actually, my 6 pin molex in the headlight shell melted on my GS1100ED.
Tech, you need to download the color wiring diagram from BassCliff's site, blow it up to 18x11, and start tracing wires. There are 1 or 2 wires in that connector that carry a significant amount of current. I don't remember which one(s) they were, and tracing the wires is painstaking work. But it will allow you to go downstream to the source of the problem and figure out a fix.
Having several colors of thin highlighter helps a lot in this effort.
I also replaced the connector with spade connectors, which is what it sounds like you are going to do as well.

[Tech73]

Sorry about not saying what bike. Yes, it's the 82 1100ez. It's the molex connector from the start button that has the loop wires plugging back into the molex.

http://i133.photobucket.com/albums/q72/instroman73/Wiring1.jpg

I've read something about it being the stator wires going up there and that it needs to be wired directly to the R/R. Is there a thread on doing this?

I will fix my sig also so I don't keep doing this. Sorry guys.

[BassCliff]

Hi,

The fix for that is simply replacing that connector and then cleaning every electrical connection and ground on the entire wiring harness. Dirty, corroded connections cause resistance and heat which melts insulation and molex connectors.

Here is one source for connectors - http://www.vintageconnections.com/ - but you may be able to find a source more convenient for you.

Read this (Regulator/Rectifier Replacement) to find out about the "useless" loop of wire from the stator to the non-existent headlight switch.


Thank you for your indulgence,

BassCliff

[Tech73]

I printed your R/R guide and will read it at work. I bought a new harness and have cleaned the connections on the existing wires so I should be good. I will also run the ground from the r/r to the battery. Thanks for the info.

KK, I'm going to do the same as you. I'm not going to worry about repinning the wires for a new molex connector. I'll also go over the wiring diagram.

[koolaid_kid]

Be sure and do that. IIRC, at least one of those wires had no use, so there is no reason to do anything with it.

[Tech73]

Be sure and do that. IIRC, at least one of those wires had no use, so there is no reason to do anything with it.

Sounds good, thanks

[Tech73]

I have everything hooked up but I have only one problem. When I cut the wires from the molex connector comming from the right control switch I didn't mark the wires to know how they plug. All the wires are yellow with white stripe but one from the harrness has red near the end. I've looked at the wiring dirgram and it looks like one is a open circuit while the other is closed. How am I to know what plug goes where and if I do plug them in wrong will it hurt anything?