Connection Problems

Here's something we've seen a lot of in the shop this year: melted and burned connectors, particularly the 3-wire connector between the stator -> reg/rectifier, and the four-wire connector that plugs into the starter solenoid. Amazingly, most of the bikes we've seen this on are still running/charging in spite of how burned up the wiring looks. However, we can assure you that it will eventually cause big, big problems. Bikes we've seen this issue on recently include a GL1200, GL500, DOHC CB 750, VT500C, amongst others. After 30+ years, dirt gets into the major charging system connectors and the increased resistance generates heat, and the cycle of connector meltdown begins. If the damage isn't too far along, our best advice is to clean thoroughly with contact cleaner and sandpaper or a small flathead screwdriver, then coat each prong with dielectric grease and reassemble. If it's too far along, we have found some sources for OEM-style connectors for many vintage bikes and can order them for you...or just use decent crimp-on ones from the hardware store, so long as you can get a tight-fitting connection.

Here is an example of when one finally fails: