Crispy Connection

[bakerhillpins]

So spring is in full swing (Finally!) and I have been commuting on the motorcycle since March. Well about 2 weeks ago at the most inopportune time of course, I go out in the AM and turn the key on the bike.. nothing. No headlights, no lights, no click, click. The only thing working is the clock. And when I push the starter it goes dead. So I find another way to the office for the last 2 weeks. I finally got the time to go out and take a look. I figured it was something simple, well catastrophically simple.    Unfortunately catastrophic is usually simple to diagnose but expensive to fix. Well, after consulting the wiring diagram in the manual I started to walk through the system starting at the battery. Battery was charged, but no power to the fuse box. Working backwards through the wiring from the fuse box I hit the starter relay and found the following:

Anyone who is into 90s Honda VFRs knows that they have remarkably under engineered electrical systems. Here is another fine example. Its the connector on the starter relay/solenoid and it connects the Regulator, Bike electrical system, and the Battery together via this connector. The connector didn't look that bad plugged in but I had to use linesman pliers to pull it out. The really nasty looking wire hanging loose is the one that feeds the bike electrical system. The other side, still melted into the connector, is from the Regulator.

So parts are on order and I will need to replace the connector and move on. Last year I had to cut out the connector to the Regulator as that did the same magical melt. Ordered parts to deal with the stator connector too while I am at it since that is another weak spot. Hope to be back riding this weekend. 

[elacruze]

Looks like they bought engineered harnesses from Moto-Guzzi. I think their inability to make wires work is why they only come with a 40w alternator.

[last426]

Yep. I had the same issue with my CBX and had to wire around the connector.  It was a pain for sure.  Kim