MOB,
You hit the cause correctly. I checked that connector and it is indeeed burn up. OK, now what's the best way to fix??? I can substitute a new type of connector. Cut the end and butt splice them. What would be really neat is to be able to get the matching pair of connentors and pins from mother Kawasaki. Of course I'm dreaming
thanks,
Yeah, that would be nice, but ain't happening...
it's a frugal fix, and easily accomplished
un ravel the taped sections of the harness on the bike side (as opposed to the generator side) and expose at least 4 inches of wire on both leads, you will end up trimming some off to get to "unburned copper'.
make sure you make a sketch of which wire connects to what color on both sides of the melted connector.Now, snip the wires and remove the connector. Trim back the wire a bit, maybe an inch on both ends, to get to cleaner copper.
Get some 14 gage wire, color doesn't matter, as you will be adding pieces to each set of wires existing. Strip the existing wires back about 1/2" on all the wires.
now cut 2 pieces of new wire, about 5 inches long,
for each lead (you will be needing 8 pieces of 14 gage wire 5" each...)
twist 2 of these new wires with each existing wire, twist them tightly....NOW SOLDER the splice, and wrap with tape, (or use heatshrink tubing if you have some) You will now have 2 pairs of leads on each harness end. you need this because in order to carry the amps, on "faston blade connections" it really requires 2 per line. Now get some male and female,
insulated crimp on blade connectors (1/4" blade), and crimp the recepticle ends on the bike side wires, and the blade ends on the generator side wires.
Insure they are securly crimped, and not loose..!!!.Plug and play back together.
I have done this repair on many Conni's and find it works well, and holds up for a long time...
do not take shortcuts though, it will result in failure.so, to re-cap:
>solder the spliced in PAIRS of wires to harness ends, 2 per wire.
>Use the correct sized wire and blade connectors (1/4" blade, 14 gage, and 14 gage wire)
>trim all junctions to find clean copper before making solder joints
>Crimp connectors tightly!
>>
do not attempt to just use 1 wire per connector,or 1 connector per existing lead, it WILL melt again...crimp on blade connectors are only good for 15 amps max, and you can pull a lot more on those wires...thats why the generator side wires have a fabric braid insulation....
good luck