Wiring information

Well, if you've been following the painful route that I've been going through with my XJ this season, you may have noticed that I've come across a new issue. It seems as though some of my wires are getting a little toasty. I know, 25 year old bike, it's bound to do that. It's a bit daunting, but I'll get through it, hopefully. One thing that I'm hoping that you guys can do for me is to help me identify the wires that seem to have a problem. I'm attaching a couple of pictures. One is a pic of the bundle of toasty wires that I have cleverly pointed out with clouds and arrows. The other is what I believe to be a faulty connector that is attached to one end of these wires. Now, I'm not sure if this connector is the actual problem, but by the looks of it, it will be soon enough. Any help with ID on these would be greatly appreciated. Thanks in advance.

 

Beard, is that a three pin connector or a 6 pin on both the pictures? Top photo looks like the feed from your alternator (hard to tell, the wires colors appear to be flash washed) . I see in the picture three white wires of larger gauge than the solenoid wires , the bottom is the connector to your voltage regulator. If these are the wires that I think they are, your damage is not uncommon and indicates either worn alternator brushes, a faulty regulator or simply corroded wires (I'm betting on the latter, but I'm sure Rick will put his money on the alternator brushes). A repair kit is available for this connector for $15 from Honda (I'll post the part number later).

 

where abouts did you get that fuse holder? thats the style i have been looking for, crappy tired didnt have it, have not really looked that hard for it but thats the one i want! The stock one... well lets just say i would like to smack the guy that thought it would work....

 

Cannon, I got the fuse block here back when I noticed that I had one fuse just dangling around in the old fuse block.

Robert, the connector in the first picture is, indeed, a 3 pin connector with white(ish) wires. The connector in the 2nd picture is an 8 pin connector with a big *ss hole in the side of it. Hope that helps in the identification?

So, where would I find those alternator brushes? I looked at old bike barn, but I couldn't find them.

 

Ok, the 8 pin connector goes to the regulator. So your pulling more amperage than the system should and the plastic is melting because of the heat generated in the connections.
Best case senario is to get a miniature sandblaster (Pasche makes the AirEraser) and clean all of the contacts. Then, using a healthy dalop of dielectric (or silicone) grease, lightly coat the contact before reinserting into the housing.
You can try BikeBandit.com for your brushes. They are out of Escondito (just north of San Diego) California and they charge a flat rate shipping fee ($7 last time I used them).

 

Oh - and that 3 pin connector is probably the one for the alternator stator.

 

Yep.

 

Does anyone know where I could get a replacement set of connectors (male/female) like the rectangle one below? Or, do you know if I could replace it with square (rather than rectangle) 9 pin connector and just leave one of the pins empty? I believe I have enough room to hide the connector by the frame if I can do this.

 

Why not use a square? As long as the pins are the same size and fit, go for it!
Sources for new connectors:
K&L (wholesaler but dealers can access them)
Fry's electronics (special order, but it works)
There are a few folks out there who can help you naming a few other places but I can't access my special list since I'm not at home.
Good luck!

 

This is pretty much what I was thinking about using. The only problem that I can see right now is that the terminal pins are not in stock and haven't been for some time. Of course, I'm sure I can find something similar to this at Fry's or some other place here. Just wasn't sure if there was some reason why I SHOULDN'T go with something like this.

 

I'll tell you why you don't want to use that connector. It's too small. Those pins are not rated for the current that the regulator is rated at. You would melt and fry your new connector shortly after installation. Here, I'm home now, let me poke around for you. I'll post some suggestions in a minute or two.

 

Here is a list:
http://mikesxs.com/mikesxs-electrical.p ... ory_id=2.6

for additional insurance:
http://wirewerksperformance.com/index.p ... x&cPath=45

 

That looks it was Jump-Started off somebody's HumVee that was runnin' on fast-idle trying to keep somebodies honey cool while the boys tried to start the bike a few times.

I got a Voltage Regulator I pulled-off a bike thinking it was the reason why the signal lights weren't flashing ... until I already put the new regulator on and found out it needed a flasher unit.

I use it to keep the Manual open to the right page. I'll send it to you to "Evaluate"

PM me the where-to:

Toasty???
Damn ... you weren't far from flames on that one connector!

 

Robert,
So, Part #12-0636 on Mikes site would be what I would want to order, right?

Rick,
You've got PM.