melting connector

I changed the fuses on my 82 xj750 today and as I was about to start the bike up after the change I noticed a connector that had melting spots on it. My first thougt was if the connector had been like that for awhile, or if it had just started. I started the bike up and noticed smoke slowly rising out of the melted holes in the connector.

My questions are
1. is it common for the connectors to go bad?
2. should I try to find a replacement connector?
3. should I remove connector and hardwire?

 

STOP.

DISCONNECT BATTERY.

Then pull that connector apart and see what's going on. Usually a connector gets hot like that because it's trying to carry a load but it's too corroded to do so.

As melted as it is, you're going to need to replace it.

Which connection is that?

 

.."changed the fuses" ..as in put in new fuses, th right amps in th right holder ..or put in new blade fuses from scratch and got th wires mixed up .. maybe?

 

I checked and rechecked my fuse replacement and all fuses and wires are appropriate.

When I was replacing the fuses I noticed the connector and wires because the set of wires leading from the engine to the connector were squished between the airbox and the battery box and this concerned me. I messed with it to see if I could reroute the wires under the air/battery boxes instead of being pinched between them. This proved to be futile as there was no slack in the wires, so I left it alone.

The wires leading from the engine to the connector are two black and one white. The wires leading out of the connector are three white wires. I dont see a connector like that on the wiring diagram that I have, which leads me to believe that maybe a PO had messed with things.

At this point I think I will just hook a new connector up accoording to the way its wired now.

 

That's the alternator STATOR output harness, and a bad rotor, corroded connector, or maybe even a bad regulator/rectifier or diode block can cause that.

Both the wires going to and from that connector should be white.

We do have the correct replacement connector shells and termianls for it.

 

should be 3 in 3 out, i might not be able to see the 3rd out.

 

So this is hopefully how this story ends...I went to the auto parts store and bought a heavy duty trailer light connector. The wires it used were a heavier gauge then the wires on the bike. I then started to dissect the plastic connector and realized it was melted together. Next I clipped wire to wire clamping and soldiering them to the new connector. While stripping the wires I found that there werent two black wires and one white running to the original connector, they were just discolored from the plastic connector melting.

The first pic is what I ended up with after all was connected and the second is after I taped everything together and tucked it all away.

The bike once again runs like a champ, and everything seems to be working as it should. Hopefully it was just a bad connector and everything is cool.

Thanks for everyones input.

 

That stator plug gets loose and corroded with time. What happened to you is pretty common.

The one from the regulator/rectifier to the main harness can do the same thing. You should check it (and really all your connectors) to make sure it's clean and tight.

 

I retrofitted those same type ATO fuse holders, but I run circuit breakers not fuses. I have a.15amp breaker in place of the 10amp fuse until I can locate a correct 10amp breaker. So far so good. I cleaned and sanded EVERY connector followed by application of dielectric grease. Ive put over 2000 miles (big deal, when I get a check Im gonna do a 800 one way NorCal jaunt) with no blown circuits.

Jay
p.s. dont forget the inline fuse thats inside the headlight bucket