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post #1 of 26 (permalink) Old 03-09-2019, 03:58 PM Thread Starter
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Electrical question

I was looking at an 86 wing today. The guy just put in a new battery and as he fired it up this connector got hot and melted. This sits next to the left side of the battery and the lower portion goes into the engine. It starts right up but it doe's not take long for these wires to start to get warm. What would cause this and how do I fix. I know I need to replace the wires.
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post #2 of 26 (permalink) Old 03-09-2019, 04:37 PM
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That's the stator connector, they are well known to go bad. If you remove the connector and solder the wires it might still charge, but it possibly has a bad stator.

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post #3 of 26 (permalink) Old 03-09-2019, 04:45 PM Thread Starter
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That is what I thought it was. How hard is it to change out the stator? Can I unplug it and run the bike to get it home?
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post #4 of 26 (permalink) Old 03-09-2019, 06:14 PM
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Changing the stator involves removing the engine (big job). The stators are still available, but I don't know about all the gaskets involved.
You can test the stator by cutting off the plug and testing the AC voltage between the wires. 1-2, 2-3, 3-1. You should get 60-70 volts AC between all of them.
If your not riding more than 5-10 miles, you may be able to get home with a fully charged battery, but that's cutting it close.

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post #5 of 26 (permalink) Old 03-10-2019, 09:35 AM
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Isn’t there an alternator modification kit for this model year to do away with the stator?

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post #6 of 26 (permalink) Old 03-10-2019, 06:15 PM
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Quote:
Originally Posted by W1ngin1t View Post
Isn’t there an alternator modification kit for this model year to do away with the stator?
i'm not sure if you can still buy the kit but you can make one yourself. I like 1200 wings but would not buy another one that didn't already have an alternator kit on it
you can send don an email and see if he still offers the kit
[email protected]
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post #7 of 26 (permalink) Old 03-11-2019, 08:51 PM
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Before doing anything, see if the contacts in the connector are tight when plugged in. You could just have the connectors arcing which causes heat and a burned connector. Years ago, my uncle had a 1200 and he spliced in an extra wire to each wire inside the connector and the heat went away. The way he did it was to use same color wires and soldered them to both sides of the connectors wires. This created two connectors doing the same as one but sharing the load in parallel.

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post #8 of 26 (permalink) Old 03-12-2019, 03:53 AM Thread Starter
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Quote:
Originally Posted by detdrbuzzard View Post
i'm not sure if you can still buy the kit but you can make one yourself. I like 1200 wings but would not buy another one that didn't already have an alternator kit on it
you can send don an email and see if he still offers the kit
[email protected]
I tried the email address and it came back as no good.
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post #9 of 26 (permalink) Old 03-12-2019, 03:57 AM Thread Starter
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Quote:
Originally Posted by TmDILL View Post
Before doing anything, see if the contacts in the connector are tight when plugged in. You could just have the connectors arcing which causes heat and a burned connector. Years ago, my uncle had a 1200 and he spliced in an extra wire to each wire inside the connector and the heat went away. The way he did it was to use same color wires and soldered them to both sides of the connectors wires. This created two connectors doing the same as one but sharing the load in parallel.
Once I get the bike home I will check it out better. If there is a fix that does not require me pulling the engine you can bet I will try it. If it is the connection that is causing the heat I can also look at replacing the entire unit with another,
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post #10 of 26 (permalink) Old 03-13-2019, 01:48 PM
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If you redo the wiring/connector, be sure to insulate and shrink wrap it.

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