REGULATOR PROBLEM

[letxbruce]

While out riding yesterday I noticed that my voltmeter dropped to 12 volts, so I headed home to do a little trouble shooting. It didn't take long to find what had happened; the connector between the alternator and regulator was fried and had melted. I supposed it could have started by high resistance caused by corrosion, or a just a failure of the regulator/rectifier. I plan to investigate the condition of the alternator. Depending on what I find it may finally be time to give in and install one of those Aussie replacement alternators.

[EMS]

That is a typical result for corroded connections which cause high resistance which cause high temperatures. Your alternator is probably still fine.

[tevan]

Where is the best place to get them connectors?

[Rick Pope]

Your Honda dealer should have everything you need, or at least the old time dealers do. Big Four Cycles in Terra Haute isn't that far from you.

If you're comfortable doing electrical work, you can repair it using common automotive connectors.

But, do it right, and do it before riding any more. A fried connector can lead to fried regulator and/or alternator. been there, paid the price.

[steve murdoch icoa #5322]

Bruce, if you do decide to eventually upgrade your alternator J.R. in Michigan makes a quality replacement.
viewtopic.php?f=60&t=8032&p=61604#p61604

[letxbruce]

Everyone, thanks for your input. I purchased two new trailer type connectors and will solder all the leads when installing. In the meanwhile, I ohmed everything out and it looked good, so I temporarily reconnected the regulator with butt splices and fired it up. The system started charging so everything is fine. A closer look at the fried connectors showed that although the contacts were clean, the problem was in the crimped connection to one of the alternator phases. A couple of years earlier the connector from the main fuse that splits from one to two wires melted down in the same fashion. I ditched the connector and just soldered the connection which moved the problem down to the next weakest link. I guess 30 + years living next to the battery caused the problems. As the corrosion increased the resistance at the connector crimps, the voltage going to the battery started dropping which in turn called for more and more juice from the alternator which heated up the bad crimp. Steve - I looked at your made in the USA Alternator and will most definitely buy one when the time comes. [embed] [/embed]