Alternator wiring

[Appie]

Good day gurus

I have a 1981 SH 96000 km bought a year ago ‘ 100% original’ according to the owner. You guys can already see where this is going…..!, transported to me, I started it to confirm it was running, which it was! I then decided to go through the bike and check it before riding

To date I have replaced engine, gear oils, removed and cleaned carburettors (only made possible with this forum) and am awaiting a shim set before I check the valve clearances and camchain tensioner. Worth noting that nothing has been easy because I’m still new to this, this bike has for sure had many hands on it over the years and I don’t want to f it up!

Fast forward to today, I’m going through electrics. There’s duct tape EVERYWHERE. Once removed , I found this. No alternator connector, I think it melted, and the 4 wires from the alternator have been soldered to the 3 leading to the reg/rectifier.

Firstly, on my wiring diagram I can only see three white wires leaving the alternator. What am I missing?Secondly two of the four white wires from the alternator are soldered together, should I trace them back to the alternator, thirdly should I replace the wires and the original connector behind the fuse box?Reading on the forums there was discussion on whether to join the alternator wires, preventing a potential site for overheating behind the fuse box.

As always any advice or comments would be greatly appreciated 🙏

[DEEBS11]

This connector kit is a good start. Might need two to get all the wires. The two shorted wires soldered together are suspect.

https://www.ebay.com/itm/255726002560?_skw=xs1100+connector&itmmeta=01JY3VX 8VC88TMR3A5MW56MY31&hash=item3b8a752180:gKsAAOSwIWdjya-h&itmprp=enc%3AAQAKAAAA8FkggFvd1GGDu0w3yXCmi1cM% 2F Ao%2FoB1FCdYJOcz%2BweDXPg20gwU%2Fq01eiU28RbrKElF2D lXrl00EC35L6CK3G2juMuytVFo7qXf378fCquF7%2B2kgE%2B8 yVwXEzC6mhTBDs%2FFOUmk6zrnEWquNtw4%2BfjCfCsbOB65e% 2FbGRqvpkUme1W0r8wuovUyLnMR5M7Aro8iVm1je3d0fkQlsII iBj%2BN%2BaXkoeuJHwPIJZHHDAsJXZDPALJnNThVFY6PUw4dj NWMQtgLsqQ9%2BsTF%2FkyP050FKJI8obJKoJwKDTQgcpPXzn6 by9nbQpTtU8aRQa9QcTzw%3D%3D%7Ctkp%3ABk9SR4SO9fvwZQ

[DEEBS11]

As you can see, those wire should not be shorted together.

[DEEBS11]

Here. This aint right.

[Appie]

Thanks Deebs11. And thank you for the link you posted first. It makes me wonder given that the bike started, was it actually charging? I didn’t run it for longer than 30sec.

I’ll go ahead and cut and separate those wires then. I have the service manual but it’s not very detailed - now is probably a good time to remove the alternator cover to check where that fourth white comes from as well and I’ll check the field and stator coil resistances.

[DiverRay]

Here is a pdf of the parts manual for your bike. It should help a lot, as you have the blow-apart of all the main components. I do have the pdf of the service manual, but it's too large to put up here. XS1100SH.pdf

[jetmechmarty]

That connector is a common problem. Once corrosion starts on the pins, the connections get hot eventually melting the connector. My bike was not an exception. The wire itself can corrode. When I repaired mine, I replaced a good bit of wire. I chose tin plated aircraft wire.
Links:

https://www.vintageconnections.com/

http://www.cycleterminal.com/motorcycle-connectors.html

XS11 uses Sumitomo connectors)

https://www.aircraftspruce.com/catalog/elpages/unshieldlwire.php

https://youtu.be/pZ809uTlENE?si=umxHuR8XieUJpxu5

[Supersport396]

Here. This aint right.

But it is a dandy soldering job!

[Appie]

Here is a pdf of the parts manual for your bike. It should help a lot, as you have the blow-apart of all the main components. I do have the pdf of the service manual, but it's too large to put up here. [ATTACH]n885122[/ATTACH]

Many thanks DiverRay that parts manual is GOLD. I have printed the service manual, it’s on the resources somewhere on this forum (Ringler US). And yes, already got parts highlighted like my old high school notes. Far more interesting though!

[Appie]

That connector is a common problem. Once corrosion starts on the pins, the connections get hot eventually melting the connector. My bike was not an exception. The wire itself can corrode. When I repaired mine, I replaced a good bit of wire. I chose tin plated aircraft wire.
Links:

https://www.vintageconnections.com/

http://www.cycleterminal.com/motorcycle-connectors.html

XS11 uses Sumitomo connectors)

https://www.aircraftspruce.com/catalog/elpages/unshieldlwire.php

https://youtu.be/pZ809uTlENE?si=umxHuR8XieUJpxu5

Thank you Marty for your help! Ok, Sumitomo connectors…and I’ll be looking at changing the wiring as well. I’ll post feedback as soon as I have something to show. I’m hesitant to ask questions because I can’t follow up on advice immediately, I’m unfortunately a bit of an armchair mechanic at present because of time constraints but I so appreciate the interest, comments and advice from everyone.

[Appie]

I found this helpful thread on the forum, it helped me understand why there are 4 wires leaving the alternator and one of these wires (smaller, yellow sheath)is unused at the alternator connector behind the fuse box on my model. But more than that it deals with alternator charging issues very well too.

https://xs11.club/forum/idle-talk-forum/xs11-xj11-discussion/48186-charging-issues?p=737305#post737305

XS11 1978/1979


And below, XS11 1980+





In case there are any novices like me scratching their heads