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Melted wire... Should I worry?

Discussion in 'XJ Technical Chat' started by apato632, May 22, 2016.

  1. apato632

    apato632 Member

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    Hi all,

    I searched the forums for this issue but I couldn't find it so I thought I'd pose it to the group. This is for an XJ650RJ.

    I removed the electrical connection for the rectifier to find melted plastic near the red wire. It was fused together quite tightly. There are no electrical problems with the bike but I am concerned that some could develop if the issue gets worse. The only electrical issue I've noticed is that the headlight dims slightly when the bike is at idle. In my experience that is normal.

    My questions are, how does the connection melt, should I be worried, and how can I fix/prevent this?

    Thank you,

    Aaron.

    Photo on 2016-05-22 at 3.50 PM.jpg
     
    apato632, May 22, 2016
    #1
  2. Jetfixer

    Jetfixer Well-Known Member

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    The recifier gets hot , a 30 year old bike probably not to bad from picture. Clean up plug reconnect see if battery is being charged, put a volt meter and check voltage before you start and after start , 12 v before and 13v running.
     
    Jetfixer, May 22, 2016
    #2
  3. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Should you be worried? No

    Should you do something about it? Yes
     
    hogfiddles, May 22, 2016
    #3
    TheCrazyGnat likes this.
  4. Mustang

    Mustang Member

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    Exact thing happened to mine, going to replace the connection with a weatherpack
     
    Mustang, May 22, 2016
    #4
  5. XJ550H

    XJ550H Well-Known Member Premium Member

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    whats a weather pack
     
    XJ550H, May 22, 2016
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  6. ant797

    ant797 Member

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    melting wires can happen when theres a bad earth somewhere
     
    ant797, May 23, 2016
    #6
  7. jmilliken

    jmilliken Well-Known Member

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    You have resistance somewhere
     
    jmilliken, May 23, 2016
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  8. Saltydog

    Saltydog Member

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    I get "resistance" from the Wife all the time regarding my bike. How do I fix that?
     
    Saltydog, May 23, 2016
    #8
    Crimson9mm, amiel1157 and Lightcs1776 like this.
  9. jmilliken

    jmilliken Well-Known Member

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    That requires an upgraded model
     
    jmilliken, May 23, 2016
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  10. jayrodoh

    jayrodoh YimYam

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    Upgraded water tight connectors. I used to use them for my custom harnesses . See them in automotive applications quite frequently.

    [​IMG]
     
    jayrodoh, May 23, 2016
    #10
    jmilliken likes this.
  11. XJ550H

    XJ550H Well-Known Member Premium Member

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    dirty connections and bad battery constantly calling for a charge.
    I see it is the red wire that melted. clean your ignition switch inside connections and external.
    Clean and lube the ignition switch
    if you have the room you could remove the red wires from VR connectors and give them a connector of their own. clean all your headlight connections and the relay that controls the headlight.
    it is the biggest current draw, then tail light connections as they are always on too.
    I went led for tail/brake light and lic plate light
     
    Last edited: May 23, 2016
    XJ550H, May 23, 2016
    #11
  12. Mustang

    Mustang Member

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    I used to use these all the time working on semi tractors, there is a pliers for them but needle nose works too
     
    Mustang, May 23, 2016
    #12

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