Voltage Regulator Question

[terse750]

I'm currently tearing down my bike for a motor swap ('01 M750) and to paint some parts while torn down.
(rearsets/ motor/ rare brake cylinder/ foot controls)

So while disconnecting the regulator and notice one of the connectors is burnt!

This is the three prong connector to the motor itself, but only one of the three prongs is fried.  

What does this mean?

It's an aftermarket MOSFET R/R I purchased less than a year ago with no apparent issues to date...

At one point with this R/R installed I had the bike running stronger than ever! (carbs tuned properly re-jetted etc.)



Here is some of the things I've been dealing with on the bike. (maybe a symptom of something being off with the R/R)

Keep in mind I have'nt had a valve adjustment in over 20,000 miles!  

It will start with certain spark plugs only!!! With the standard NGK's recommended for the coils it won't crank anymore.

I tried an E3.36 plug for the hell of it, I was tired of fouling plugs ever few weeks with the NGK's.

It started AMAZINGLY! I knew this wasn't right deep down but wanted to ride...

After a month or so it started fouling the E3.36 multi tip plugs. ( I limped home one day on one cylinder recently)

What are the three prongs from the motor plug to the R/R plug for, and what may be the reason for the burnt connection?

Is my R/R toast?  

[bdfinally]

That's from your stator. Check out the last page of this flow chart.

[oldndumb]

Excessive resistance equals heat.

Common occurrence with that particular connector. The fix is to use a MetriPack 280, or equivalent.

[Howie]

You also need to replace any wire that is not still copper colored.  Then recheck charging system.  Yes, this could cause your other problems.

[oldndumb]

You also need to replace any wire that is not still copper colored.  Then recheck charging system.  Yes, this could cause your other problems.

Yes, re the wire. You might be surprised to see how far any discoloration goes under the insulation.

Take Howie's advice. He knows where the electrons hide out and may wander off to.

Accurate charge system trouble shooting can be done once the connector and any discolored wiring is replaced. While I think it most likely the discolored connector is the cause, it also could be a symptom. Remember, a fully charged battery is necessary to do the tests.

[terse750]

Thanks for the help. I got the recommended connector. So I'll get the wire as needed.
It's been raining the last few days here and haven't gotten to work on her much.
I'm hoping my r/r is ok.