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

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

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

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

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.

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.

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.

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.

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...