reg/rec wires melted is it duffed?

[JORDAN8710]

Hi, ive been doing a rebuild which I started for the first time today but after a couple of minutes the reg/rec wires melted together at the rhs multi plug. When I had the loom stripped before I saw that it had been a bit melted but I repaired it. Now its happened again but much worse. Would this suggest that the reg is nackered or could it be a bad earth somewhere? Any help would be appreciated as I don't know much about the reg/rec.
Thanks Jordan

[bikemonkey]

Post a picture up of the burnt bits.

Follow this charging system checking guide: http://www.electrosport.com/media/pdf/f ... iagram.pdf

You'll need a multimeter, something to jot your readings down on, and a bit of patience.

If you can't conclude what's wrong by using the guide then post your findings back here and the electric nerds will know

[CMSMJ1]

you need to sort the cause and the symptoms too.

As Mr monkey says - check the system but also get some new connectors, or solder and heat shrink the wiring directly.

Melted plugs = your system telling you it is going to die

[Morespeedvicar]

If its melting plugs theres something else up like mark says, i'd do a quick charging check, it sounds like there a short somewere in the rec if the wirings getting that hot and dont use it till you've checked it out.
Cheers
Ian

[JORDAN8710]

Thanks for the replies, This was what I found when I first started stripping the bike a while ago.

I Just assumed that the wires had melted due to a dodgy wiring repair so I just ordered new connectors and repaired them.

And this is what happened.
I haven't checked the multiplug at the reg yet. Am I right in thinking that the yellow wires can go anywhere?? because when I wired up the plug I just put them anywhere. The reason I Thought it might be a dodgy earth is because I have just had the frame powder coated. Ill do a charging system check today and post my findings.

[magg]

I would not recommend the normal charging system check as it requires you to run the bike with the charging system all connected and you already have a problem because it is burning the wire insulation.

Suggest you disconnect the rect/reg and measure the resistance between the rect/reg terminals that normally connect to the three yellow wires. You should measure infinite resistance between all the three terminals. From the symptoms of your problem, I would expect that the resistance to be zero between at least one pair of terminals and this indicates a dud rect/reg.

[JORDAN8710]

Thanks for the sound advise magg. I checked the resistance between the yellow terminals and right enough there was continuity between two of the 3. The others had a resistance of around 0.4 ohms though so dunno what that means. I think it would prob be safe enough for me to start sourcing another one though eh.

[speedy231278]

So, are you saying the wires from the alternator have 0.4 Ohm resistance between each pair? That's fine. Continuity between any of the three input pins on the reg/rec means open the bin and throw it away. There's a short in it, and that's what is causing the wires to burn. Have the reg/green wires coming from the reg/rec also burned and/or have they burned the connector? If so, I would strongly recommend taking the battery off of the bike, giving it a full charge, and then checking the charge over the course of a week to see if it discharges rapidly. There's a chance that if the wires on the output side have burned, it was over charging the system, and this can lead to battery damage and poor performance.

[speedy231278]

As an aside, the lack of fins on a reg/rec for a 30/35 should be avoided as they are prone to overheating and things like this can happen as a result. It's pretty rare to see brand new ones without fins, so you should be OK. Don't buy a really cheap one, either! You get what you pay for, and if it's cheap, it'll probably break down...