Stator wire bullet connector overheating

[Guest]

Hi all, I have an '82 gs650 Katana and a U.S spec gs650g on both bikes the stator bullet connections to rectifier block connector are overheating, any ideas?
Steve

[fastbysuzuki]

Bit of a coincidence on both bikes, have you checked what voltage (at the battery terminals) you are getting when the bikes are running both at idle and at 5000 rpm?
Usually Heat is caused by over charging or dirty/poor connections bad earths.
any doubt about the charging system have a look at the charging quick test

https://www.thegsresources.com/_forum/showthread.php?164993-Charging-System-QUICK-TEST/page9&p=1272192#post1272192

do those tests and post the figures on here.

more info on stator pages https://www.thegsresources.com/_foru...31#post1138531

[s-john1]

I think I've sussed it, the bikes run fine without any charging problems, checked fuse box block connectors and all the other connections bit of corrosion and crud in them all! but I am going to renew the bullet and block connectors. is it worth putting the w/g and w/r wires through the block connector and bypassing the connector in the light circuit which comes back on itself.

[Nessism]

Standard forum wisdom here includes installing a SH775 R/R and feeding the stator wires directly into the R/R, bypassing the stock connectors.

[Redman]

.......
.................is it worth putting the w/g and w/r wires through the block connector and bypassing the connector in the light circuit which comes back on itself.

Yes.
That is still in the design of the wiring harness (loom) from when there was a headlight switch.
Yes, Wire stator directly to the r/r.

[s-john1]

Rather keep the U.S 650g original, came from Colorado and shipped over a few months ago and is nigh on A1 condition after I gave it a good wash and brush up with 4000 miles on the clock. Engine is sweet as a nut. Not bad for 37 yrs old ay!

[s-john1]

Cheers for the info guys.

[s-john1]

Update

Cheers for the info guys.

Replaced blade connectors in the block connections and and bullet connectors for stator r/r and fuse box as there was a fair bit of corrosion on connectors and wires. all working properly now. also bypassed the light circuit.

[posplayr]

Replaced blade connectors in the block connections and and bullet connectors for stator r/r and fuse box as there was a fair bit of corrosion on connectors and wires. all working properly now. also bypassed the light circuit.

The connectors got hot because you allowed the to get corroded. They need something like depot as a chemical etching and surface prep.

[s-john1]

The connectors got hot because you allowed the to get corroded. They need something like depot as a chemical etching and surface prep.

The U.S spec 650 came from Colorado earlier this year so most of the connection are great, but the '82 650 katana was left neglected in a hedge and damp shed from 1990 to 2014 when I got it. Now restored to its former glory.

[posplayr]

The U.S spec 650 came from Colorado earlier this year so most of the connection are great, but the '82 650 katana was left neglected in a hedge and damp shed from 1990 to 2014 when I got it. Now restored to its former glory.

https://www.thegsresources.com/_forum/showthread.php?237763-Recommended-Products-for-Preparing-Electrical-Connenctions&highlight=corrosion