Charging System Badly burned alt plug

[Ljay40]

Just wondering if anyone had any iput on this problem

Recently rode into town and fueled up then came back shut off the bike go to restart the,bike and she barely turns over Wow said to myself so time to do some investagating threw on the voltage meter and found out im not charging so threw on the spare regualator/rectifier still no change pulled the white wires out from behind the fuse block WHollly Crap they are all melted the whole plug I thought oh no just blew my igniton out,So I had to cut the plug out and spliced them all back together I belive there was 3 white wires the forth was green did not do anything
seeemed like a dead end in the plug,anyhow the bike now charges although I have to hit about 5 grand to bring it up to 14.5 volts
other wise it charges just over 12.5 and creeps up as the revs increase I cant member what if charged at before all this
Did I damage my alternator? thus the weak charging now Why did it not blow out a main fuse or something and what could have caused all that heat to melt that plug so bad ,the battery is like almost brand new Perhaps regulator lettting to much voltage thru all though it was alternator wires burnt Im kinda stumped as to what exactly caused this I did wash the bike the day before,perhpas water all conections had die electric grease on them
any Ideas
TIA
LJaY

[DiverRay]

Ljay,
It's just old age and use frying the connectors. The STOCK reg/rec didn't charge well until 5K, but Geezers starts working fully at 2.5K. He also has the replacement plugs and connectors, so you can just replace the old one.
The problem is as the bike gets older, the resistance goes up in the connections, and they heat up. This increases the resistance, and so on. I've put new connectors on both my daily ride, and E.Liberty's '79 special. They BOTH charged better after, but on my bike I also installed Geezers Reg/Rec. Dramatic improvement!!

[Brian_D]

that unused green wire was the direct feed to the headlight relay on the 78-79 models....the later models have a hidden diode that taps one of the white wires to feed the headlight relay.

[Geezer]

Actually the reg/rec units I build give full charging by 1500 RPM (usually at 1200 RPM.)

Anyway the OEM connections corrode and fry because the terminals weren't coated in dielectric grease from the factory like done on later model bikes.

Clean or replace the connections and pack them with dielectric grease.

Geezer