1982 Yamaha XJ750 Maxim Alternator

Bike: 1982 XJ750 Maxim

I'm looking for a little direction. The alternator is draining the battery when it idles. The alternator passed the voltmeter test. While going through the check list I attempted to pull the Stator plugs apart. After a couple choice words and some serious grunting I was able to pull the plugs apart.

It appears the male and female ends of the plug melted together.

I pulled the tape back and the wiring looks good. Any ideas on where to look next to repair the issue?

Also, since there is very little wire can I repair it with pigtails or do I need to run home runs? As always, any help is appreciated.

 

just splice, solder and shrink wrap them. that's a common problem, some look way worse than yours. you caught it early.
the wires can go together in any order

 

it is your headlight that draws the battery down at idle.
Bad connections do not help go through the connectors with contact cleaner and use dielectric grease.
how old is the battery? when batteries get old they charge quick and drop quick.
what kind of voltage drop do you get when you start bike?

you should ohm out the charging system

 

Thanks

 

Thanks. I failed to mention what I've already done. The battery is new (April), the alternator tests out, the voltage drops only at idle. The resting battery and revved up works within tolerances. This connection was arcing so I'm hoping that is the only issue.

Appreciate the advice.

 

Honda made an alternator plug repair kit for Goldwing
Look almost identical to that. Comes with the male and female plugs with about 8" of pigtails and solder and shrink tube
About 10$ from any Honda dealer
Part# 31105-ml8-305

 

Perfect! Thanks for the tip.

 

Even a Honda car dealer can order that if no bike dealer nearby

 

Or you can order from Chacal info@xj4ever.com

http://www.xjbikes.com/forums/threads/xj-parts-catalog-section-d-electrical-system.44641/

Looks like he carries all the parts like individual terminals, connectors, and even similar wire if needed.

The cleanest repair if there is sufficient wire length would be to cut the original connectors off, install new terminals and connectors, and it would be just like factory.

Or go to Ebay - search the part number and many appear. Cost ranges from about $20 to $40 with shipping.