You may find that at some point in the bikes life it's eaten a few rectifier's. If this is the case the plug can take a battering with heat and they often "fuse" together. It's worth checking them on a regular basis if you suspect electrical problems.

Push the tab on the plug and tug very hard...


Cheap enough to replace http://www.ebay.co.uk/itm/Connector-Plu ... 43c066eb92

check the correct size of spade connectors first and I always blob a bit of solder on before crimping.

Even with a new connecter from eBay (I just replaced mine) they need a good squeeze and wiggle/pull to get out..

Okay so my reg/rec is stuffed and the connector melted




Which in turn, I'm guessing, stuffed my battery. I should've checked this a while ago as I smelt wire burning like a couple months ago when I was riding....but I couldn't pinpoint it so I kept riding, eughh...i feel so stupid.

I'll get that heavy duty rectifier from Rick O, I need needle shims anyway..... As for the connector, what size is the spade, and how do I solder and replace the plugs?

I put the reg/rec back in though, I need to ride the bike about 300 meters uphill to a new parking spot.

I would get. New connecter on eBay and just cut off the old one and wire it in?

So i've installed a new Reg from Rick, and that stopped the overcharging, however after riding, the battery still goes dead flat, I bump start and bikes perfectly fine, it's just the battery going totally dead, I think I should have just replaced the battery along with the reg/rec (bikes charging and everything), any other suggestions?

Yeah sounds like your battery has died, try charging it up over night, then measure its voltage with the lights on but with engine not running.

I got 12.2 volts, will install a new battery and then see how i'll go. Bike runs absolutely fine when running, its just the battery dying. It could be that my stator may be burnt out so that it's not charging enough to keep the battery afloat, I ran the test after i installed the battery and it was getting like 13.3 and then slowly climbing to 13.8, pretty crap,I had the stator rewound 1.5 years ago by a dealership but then again it was under warranty and could have been a dodgy job, they were dodgy people to deal with, if the new battery is still going flat, will have to physically inspect the stator itself...sigh...

13.8 should be okay ish? Mine does that with lights on (we have to ride with them on all the time) and haven't had an issue?

So good battery is in, tested the charging, and it's only charging at 13.3-6 v at 5500-6000 rpm. I think it's time to take a physical look at the stator.