New Electrical problem on XJ1100

[gmups]

Ok, this is a question for you XJ electrical guru on the forum. While replacing a faulty side stand switch, I was unplugging it from it's connection under the gas tank when I came across this other (melted together) connection. here are three pics showing first one showing worst side(melted), second the other side(3 white wires), the third showing the whole (melted) connection from the side.







Now the question, what plug is this? How should I go about fixing this? Just replace the connection and wiring?? Thanks..

[DGXSER]

Three large white wires on this bike is the alternator connection, should be the same on your XJ. I would suggest contacting Geezer ...aka...Oregon Motorcyle Parts. He sells the direct replacements for the connectors on our bikes. But I would definitely replace the entire connector and remove the burnt up part of those wires.

This is not an uncommon thing to happen on these bikes. Typically caused by dirty/corroded connections it seems.

[crazy steve]

The plug is the connection from the alternator stator to the voltage regulator, and this is a common failure point. The connections get dirty/corroded, won't carry the needed current and melt. One of the members here (Geezer) sells new replacements for these, and has a nice tutorial how-to. Send him a PM and he'll fix you up...

Checking/cleaning all connectors on these bikes can be critical to electrical health...

[gmups]

Thanks guys..



Thanks guys, I have already contacted Geezer via PM, however I mistakingly thought it was a Stator plug?? Hope Geezer comes across this post, otherwise I will PM him again as to what I need..thanks..

[Geezer]

That's the 4pml and 4pfl plugs on my website....

http://www.oregonmotorcycleparts.com/connectors.html

Geezer

[gmups]

The right plug..

Thanks Geezer, my order is in, thanks for the quick replies..

[Geezer]

No worries. I would have posted sooner but I'm rather exhausted lately. Spring as sprung early in the bike parts business even if the weather still sucks...

Geezer

[gmups]

Just a followup..

Geezer,

Thanks for getting the parts to me fast. Everything went fine. Reconnected wires leading to Alternator (stator). Looks just like the orig only better, used dielectric grease on everything. Started her up and got the meter out 12.48 on idling and rev to 3000 got 14.68. Shes charging, and starts a lot better than ever before!! thanks for all the pointers my XS/XJ friends.

[Geezer]

I'm always happy to help.

Geezer