electrical trouble again

[floridajoe]

back on 8/24 you guys helped me. i had fried wires to main switch. rewired and was great and now melt down again. where do in go from here. thanks all

[LoserShoes]

There are two reasons wires will melt, too much current, and too much resistence.

If the wires are melted right up next to the switch, the connectors or the contacts in the switch are dirty,and need to be cleaned and or the switch replaced.

If the wires are melted in kinda random places and not just near the switch, you have a bad component or short in the wiring harness and will have to find that.

Can you post a picture?

Steve

[floridajoe]

sorry no pictures. melted at the connector . redid wires my headlight is brighter now. had a friend check charging system working fine. i think i need to go thru all connectors and clean them. what is the best way to do it thanks all joe

[Geezer]

The problem is high resistance at all the plugs drawing more power through the connections. All the power from the bike goes through that plug (where the brown and red wires connect) and it takes the most abuse.

Clean all the terminals and coat them with dielectic grease. It's a PITA and will take all day to do but you only have to do it once every 30 years or so...

I put a new plug on the Mongrel and it was long over due... I'm out of 4 wire plug (I have a shipment of them on the way from Taiwan) but I put a 6 wire plug on mine and left the 2 center holes empty.

Geezer

[LoserShoes]

I've been useing some "CRC QD Electronic Cleaner" from an auto parts store, and it seems to work well on connectors. The best was is to remove the contacts from the shell and clean them with fine sandpaper, but that can be a real pita.

Steve

[Geezer]

I wouldn't use sandpaper to clean the terminals because it takes too much material off. A small wire brush is better.

Yes it's a PITA to remove all the terminals from the plugs but sometimes there's no other way to do it right. Also if you coat the terminals in dielectric grease after you clean them, you won't have to do it again.

Geezer

[floridajoe]

thanks great info spend this weekend coming up doing that, plus my intakes are bad and pick up i will be busy
thanks again all