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Discussion Starter #1
So since getting the bike, I've been having charging issues. But I thought that was the least of my issues. Yesterday, while out leaving, suddenly the bike wouldn't start again. I check the starter solenoid, and the fuse is blown. No problem, I replace it, but yet still no power.

I get the bike home on a trailer, pull the seat off, and attach the charger just for laughs. Suddenly... Power! But it wont start, you can hear the relay tripping like the speed of light. Hmm...

I dig deeper and tear of the side to look at the previous owner's wiring job, and my jaw hit the floor.

Everything is direct wired to the components. The rectifier is connected directly with spade terminals. Same with the starter.

So now I'm undertaking the task of replacing all the damaged components. Anyone know where I can get the factory connectors? The factor plugs?

While I'm working on this, I'm basically going to be replacing the entire back set of wiring, the starter solenoid, the rectifier, and the stator. Any tips on getting out of this the easier/cheapest?
 

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All the connectirs are available in some form or another on eBay. I got mine right from Honda, but that was by my choice. But I'm not sure about the starter relay connector.






The starter solenoid connector is available as well on eBay. There have been a few guys here to buy all 3. Look at Manishway's posts about his charging/wiring problems. Same stuff you're going through.
 

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yeah you can find all the connectors on ebay pretty easy. they are cheap to buy as well. just do a good job when you put them in place. i personally would recommend heat shrink tubing and a good soldering. they make some pretty crazy connectors these days that have a conductive grease built right into them that might be ok to keep the elements out and the corrosion at bay. but cheap butt connectors being different type a metal with al, that current running thru them wont hold up well.
 

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lol those pics are a perfect example of how not to rewire a honda charging system! i have seen worse, ill say that. i worked on a friends gsxr 750 that had a melt down n when i got in there, im not joking, there was wiring from a house lamp running from the stator to the r/r n where it had been chopped into the original harness the wires were twisted together, covered in black tape and had pieces of wood in between each of the three yellow wires keeping them apart. lol the black tape was so hard from being melted into the twisted wires it crumbled apart like a dirt clod of something. made yours look like a pro job.
 

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here are some a those gel filled connectors i mentioned. to be honest i havent used them on this kinda application. they are as mentioned gel filled to keep out the elements and self stripping so you basically just put the wire in and push it closed n it locks together. they are flame and heat resistant. i still think just solder n heat shrink tube is best but if you must use a connector i think id try something like these out

3M Scotchlok 314 IDC Connector 50 Piece Box | eBay
 

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Discussion Starter #7
I'll look into soldering them. Granted, I literally have a warehouse full of different butt connectors, electrical tape, and other electrician tools. Working for an electrical contractor has it's ups and downs.
 

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Discussion Starter #8
I've gone ahead and ordered a new stator, rectifier, starter relay, and harnesses for both. Should be in sometime in the next week or so. Then we get to play the magical game of "did I kill my ecu with this shoddy wiring?"
 
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