[seans85]

I just got a Honda Magna 700 with a melted connector for the stator. The terminals came out of the connector and i dont know which is which. They are 3 yellow wires and I cant see which went to which. Anyone know how to match them up?

 

[Wild Willy]

It doesn't matter. Here is a copied post Login from the Honda bbs Honda Sabre, Magna, Interceptor BBS - Index



Re: Connector meltdown from Alternator - AKA the 3 wire fix
« Reply #1 on: July 04, 2011, 12:28:43 PM »


Honda sells an "ACG connector repair kit" for around $15 list. Some list members report this works well, others that the replacement also failed. (2) Replace the connector with crimp-on spade or bullet connectors.



Some list members report success, others that this also fails unless the connectors are soldered. Dispense with the connectors altogether, solder the wires, and cover them with shrink tubing. This appears to totally eliminate the problem. Mild disadvantage on Magnas: to remove the battery you have to remove both the bottom and top bolts of the battery retaining bracket, to which the regulator/rectifier also is mounted. BTW it doesn't matter if you get the 3 yellow wires from the alternator mixed up from the way they originally were

 

[Wild Willy]

By the way this is a common problem. The best way is to solder the wires. It doesn't matter if you don't get the wires the same as they were just reconnect them. It helps if you ad a few inches of wire. Be sure to use the same size wire.
I have preformed this fix on both my Magna's. I hope this helps.

 

[Easy Rider]

It doesn't matter.

By the way this is a common problem. The best way is to solder the wires.

Wow.....I didn't realize that the problem goes back THAT far.
Recent model Hondas continue to have that same problem.

The good news, as above, is that the fix is fairly easy.
The BAD news is that by the time the connector and contacts are burnt up really bad, the stator often is gone too.

I'd suggest making a solid temporary connection first.....like with wire nuts maybe......and testing the charging voltage before soldering it all together and shrink-sleeving the connections.

 

[Wild Willy]

Wow.....I didn't realize that the problem goes back THAT far.
Recent model Hondas continue to have that same problem.

The good news, as above, is that the fix is fairly easy.
The BAD news is that by the time the connector and contacts are burnt up really bad, the stator is gone too.

I'd suggest making a solid temporary connection first.....like with wire nuts maybe......and testing the charging voltage before soldering it all together and shrink-sleeving the connections.

I started to post something else, saying what you said but then realized you already said it.

 

[Easy Rider]

I started to post something else, saying what you said but then realized you already said it.

lus1: What HE said !! :lol4:

 

[RevJoel]

I love resurrecting old threads...instead of creating new threads about issues already discussed.

My Vulcan has been running great since I got back from my 5,400-mile trek around our great country. Last week, I fired her up to run an errand and saw smoke coming from the stator connector housing. I turned it off immediately and removed the cover to discover one of the three connectors had melted. It has been suggested to solder them as others were saying on this thread but as Easy suggested, should I temporarily connect the three with bolts, etc then test voltages before soldering?

As I said, it's been running great. The stator is from Ricks so I know it's a quality item and only has about 8k on it. Thoughts?

(Honestly wondering about these 2006 Vulcan 900s if something was just not right in the design this first year. Maybe I should fix and sell....)

 

[Easy Rider]

(Honestly wondering about these 2006 Vulcan 900s if something was just not right in the design this first year. Maybe I should fix and sell....)

Naw.....it's a great bike.

Seems as though a LOT of metric bike makers undersized the connectors for the stator.
Then just the tiniest bit of loosness and it heats up ....more and more as time goes along until melt down.

Exactly how you go about testing and repairing depends on your skill with a soldering iron.
A wire nut is a good temporary option if there is enough slack in the wires.
Even a bolt or alligator clip should work for a quick test.

Of course, the burnt wires will need to be scraped clean first.

If that looks good, do all 3 of them.

Might have been a good idea to solder them after you knew you had a good stator but hopefully no harm is done beyond the wires.

 

[RevJoel]

Skill with a soldering iron? That would be a resounding "None." I'm hesitant to take it back to West Orlando Powersports who installed it.

I don't think anything is wrong as it's been running great unless I just happened to catch it as something (stator or rectifier) was going bad. May have to see if there is a mobile mechanic around that can assist. I think I'm done with dealerships.