Hi

Looking under the seat today I can see that three electrical connectors have overheated to the point of melting. I think they are wires from the regulator rectifier... any idea what might be causing this?

I am not knowledgeable about motorcycle electrics ... so keep it simple please!

The regulator wire carry quite a high current and oxidation of the connector surfaces will create resistance which in turn generates heat which will encourage more oxidation making the situation worse with the result that the connectors eventually burn out, the insulation melts or the resistance gets so high that no current flows. You potentially risk a fire and most certainly a non-charging battery.
Replace all the connectors on both sides of the junction with good quality items that are more than up to the electrical current requirement. Also replace any damaged wiring, again using suitably heavy duty wire.

Thanks Derek

That is very helpful.

Anyone able to suggest a good quality connector and supplier in the UK?

This forum is super helpful... thanks Pasoists

I regularly deal with these firms;
http://www.vehicle-wiring-products.eu/
http://www.polevolt.co.uk/
https://kojaycat.co.uk/

Their products cover a wide range of general and specialist applications. I use whichever one has what I need at the best price at any time.

Hi

Thanks for the links.

Replaced the melted connectors and it looked like one was broken but just touching.

Bike now not charging... so I need to try and work through that.

Ok... so I just want a basic charging circuit. I have bought a generic 5 wire reg/rec and connected the two yellow and red wire from the stator, linked the live and wired the ground to the battery. I have charge.

Is this ok to do? Will I combust?

Thanks in advance...