Fuse box connector, burn marks?

[jprice90]

I'm guessing these are burn marks.
I'm not at my bike right now and forget how the wiring is setup, but could someone shed some light and maybe tell me what I should look into?

I got everything to start digging into this regulator swap, SHOULD have it done by early next week.

[Joe Garfield]

You don't think it's corrosion from some kind of liquid getting in there?

[jprice90]

I suppose it could be, but then I would think more of them would have it
the plugs have no signs of any burns, which is good

when I put everything back together I'll make sure to put a good amount of dielectric in the connectors

[posplayr]

Clean it up and the more pitting you see the more likely it is a burn. If it is burning you probably should change out those contacts (harness plug).

Another clue is what does the other side look like? Similar I expect.

[jprice90]

damn, what connectors do these 2 go to?
The plug itself looks ok, I seen a little spot on one of the connectors but nothing like WHOA

[Guest]

That side of the plug doesn't look too bad to you, but what does the other side of the plug look like where you can't see it? replace them. Heat damage just gets worse.

[Guest]

If it was heat related, wouldn't the plastic of the connector block show some signs too? It appears very close.

[Guest]

It's the other side of the connection that might be damaged more. those spades are pretty thick and only damaged on one side, but it took some high heat to eat through the coating on the spades.

[jprice90]

That side of the plug doesn't look too bad to you, but what does the other side of the plug look like where you can't see it? replace them. Heat damage just gets worse.

you mean replace the plug end? from the harness?

[Guest]

Yes, the harness plug. There is no melted plastic where the spades are molded into the fuse box, so the heat damage is most likely in the harness plug connectors. I imagine the two terminals in the plug could be replaced. At the very least you should clean everything up with DeoxIT D5 and put dielectric grease in the plug to seal it. However I would keep it in the back of your mind that their might be a failure down the road, and that might leave you stranded.

[jprice90]

Yes, the harness plug. There is no melted plastic where the spades are molded into the fuse box, so the heat damage is most likely in the harness plug connectors. I imagine the two terminals in the plug could be replaced. At the very least you should clean everything up with DeoxIT D5 and put dielectric grease in the plug to seal it. However I would keep it in the back of your mind that their might be a failure down the road, and that might leave you stranded.

My bike is currently in a storage unit so I don't get to look at it much anymore, but it's better there.
I checked out the plugs a little further, what I gathered is the solid Orange and White/Orange are the ones that are burnt, WH/OR a little worse.

[Guest]

Orange is switched power from the ignition switch and orange/white the ignition system. Here is a link to a wiring diagram that should be very similar to yours: http://members.dslextreme.com/users/..._color-new.png

[jprice90]

Orange is switched power from the ignition switch and orange/white the ignition system. Here is a link to a wiring diagram that should be very similar to yours: http://members.dslextreme.com/users/..._color-new.png

Thank you
I had checked out the Ignitor unit as well, that looks good
I'll look further into this. any idea why this wouldve happened? When I first bought the bike the main fuse was popped. but ever since replacing I havent had one issue

[Guest]

Probably because of high contact resistances building up in connectors and switches, possible poor grounds, etc. The bike is old enough to require a total electrical system cleanup, DeoxIT D5 on all the bullet connectors and plugs to soak into the crimp connectors to remove corrosion and reassemble with dielectric grease to help keep out moisture. Switches and grounds also need to be cleaned up as well as the fuse box. The weakest points in the electrical system will be where heat damage shows up as a result of the cumulative high contact resistances. Carefully inspect for burnt connectors and feel all plugs with loads on the circuits for excess warmth, indicating high contact resistance. Replace what is obviously damaged and eventually plan on replacing the fuse box. I haven't had time yet to replace all my old plug connectors, but it is on the to do list. I also have a series R/R so I was able to reduce load by converting my headlight to a Cree LED H4 conversion (not recommended with a shunt type R/R, it can fool it into overcharging).