Hi

The 3 yellow lines connecting my generator to the regulator have corroded through at the connection yet again, this is not the first time its happened and my bike never really gets wet.

Is this a common fault or something to do with the wires getting hot?
Are there any preventative measures I can make to prevent it happening again?

Thanks

Adrian

I would say upgrade some of your lighting. LED's for signals should pull less amps.

HID instead of bulbs.
2 standard bulbs= 60watts
hids 35 w max

+1 on LEDs use less than any bulb.

I think you more likely have a more simple problem with the charging system.

Replace that 3-plug with one of these:
http://cgi.ebay.co.uk/Motorcycle-Electr ... 27b304067e

it is identical to the honda part, I used one on my CB-1. Fill it with silicon grease to keep corrosion away. You can also replace the wire, e.g. cut near to the alternator put the plug near the engine and use a longer section of thicker wire. You can get that from vehiclewiringproducts, I would start with Ref33, this will be overkill but that's better than too thin as that gets hots, which again causes you problems.

You can also replace the regulator plug, or just the terminals in it. The 3 for the yellow wires are FBL 6, the two others are FBL8. Or you can get the plug as an assembly from eBay.

Take the regulator off the bike, clean the back, fit it back on with silicon grease (CPU heatsink paste is better) to remove any air gaps. Clean off the main earth connection, and if possible run it direct to the battery.

All these things will help keep you charging system healthy. Corroded plugs in the charging system is what will help it go into meltdown then if you are unlucky it gets expensive quickly.

& if you dont have silicon grease. a wedge of Vaseline will also do!

leopard_pagan wrote:& if you dont have silicon grease. a wedge of Vaseline will also do!

Whilst this is true, it's also kinda not. Vaseline is petroleum based, so will tend to rot connector housing and harden wire insulation. Not recommended, in honesty. But still better than nothing, as the damage will take years to become apparent.