Burnt regulator connector - ZX6R Forum
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post #1 of 13 Old 05-17-2017, 03:05 PM Thread Starter
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Burnt regulator connector



I can only imagine that this could be why my bike won't stay charged ? It's from the regulator into the main wire harness.


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post #2 of 13 Old 05-17-2017, 04:09 PM
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That's usually a secondary concern..... the reason it got so hot as to melt the plug, means the alternator had to produce a LOT of power for an extended period. It could very well be burnt up.

Don't just treat the symptom.... find the actual cause.

The shop manual for your bike, and a multimeter will get you there in less than an hour.
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post #3 of 13 Old 05-17-2017, 04:29 PM Thread Starter
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Originally Posted by RJ2112 View Post
That's usually a secondary concern..... the reason it got so hot as to melt the plug, means the alternator had to produce a LOT of power for an extended period. It could very well be burnt up.



Don't just treat the symptom.... find the actual cause.



The shop manual for your bike, and a multimeter will get you there in less than an hour.

Well I just bought the bike a week ago. After I bought it it crapped out on me about 20 mins after I bought it. Bought a new battery and died again within 30 mins. Then replaced the stator and it ran for about 8 hours then it died again. So today I pulled the regulator and found that the connector on both regulator and main harness engine harness had fried. So would that mean it's the whole regulator itself ?



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post #4 of 13 Old 05-17-2017, 04:30 PM Thread Starter
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The connector between regulator and stator were fine


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post #5 of 13 Old 05-17-2017, 04:33 PM
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I'd guess the regulator has failed, and that it's running WFO.... which fries the stator (fixed part of alternator)..... if there are any corroded contacts in any of the connectors anywhere in the path, they add resistance which makes additional heat.

Best answer is to use that Multimeter we keep mentioning, and solve the problem based on facts instead of guesses. Honest, it's less expensive that way.

"Basic stuff fellas. Use your head for something other than to break your next fall."

"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #6 of 13 Old 05-17-2017, 04:39 PM Thread Starter
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I'd guess the regulator has failed, and that it's running WFO.... which fries the stator (fixed part of alternator)..... if there are any corroded contacts in any of the connectors anywhere in the path, they add resistance which makes additional heat.



Best answer is to use that Multimeter we keep mentioning, and solve the problem based on facts instead of guesses. Honest, it's less expensive that way.


Well considering I already have another regulator showing up tomorrow I don't mind spending money. I know the mulitmeter would help but still not sure how many volts I'm looking for from where and what rpm and so forth. But im afraid that connector won't work if I plug it in to the new regulator and was thinking of cutting that burnt wire out and hardwiring it into the other side. I'm decent mechanically with cars but this would be my first bike....similar but different


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post #7 of 13 Old 05-17-2017, 04:49 PM
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What year is the bike?

Find your service manual here download it for free. It's the best free advice you will ever get.

"Basic stuff fellas. Use your head for something other than to break your next fall."

"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #8 of 13 Old 05-17-2017, 04:52 PM Thread Starter
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2003, and yea just looked at the manual. But the manual won't tell me if that connector is dead or not....only experience haha


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post #9 of 13 Old 05-17-2017, 04:54 PM
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Since you have several unknowns. Clean all your power connections.
Pay special attention to the ground on the bike. Would not be surprised if the negative lead to the frame was corroded.
On a 12 volt system the ground is just as important as the positive lead.
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post #10 of 13 Old 05-17-2017, 05:01 PM Thread Starter
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Since you have several unknowns. Clean all your power connections.

Pay special attention to the ground on the bike. Would not be surprised if the negative lead to the frame was corroded.

On a 12 volt system the ground is just as important as the positive lead.


So basically just follow wires everywhere and make sure they're not corroded or burnt up and secured tightly to whatever they're on ?


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post #11 of 13 Old 05-17-2017, 07:21 PM
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This was a common problem on the early Ducati 916 bikes. The only solution in that situation was to cut out the connectors and hard wire. The stock connectors would get corroded and increase electrical resistance, resulting in more heat ... a viscous cycle that continued until the connector melted and the bike would die, leaving you stranded (happened to me).

I don't know if this is common to 2003 Zx6r's or not though...
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post #12 of 13 Old 05-17-2017, 07:56 PM
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Originally Posted by thiskidohno View Post
So basically just follow wires everywhere and make sure they're not corroded or burnt up and secured tightly to whatever they're on ?


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Just the charging circuit and starter system.
Stator to regulator, regulator to battery.
Battery to starter solenoid, solenoid to starter, Battery to frame ground.

While poking around, look for butcher job's, burnt or bare wires.
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post #13 of 13 Old 05-17-2017, 07:59 PM Thread Starter
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Originally Posted by Duc995 View Post
This was a common problem on the early Ducati 916 bikes. The only solution in that situation was to cut out the connectors and hard wire. The stock connectors would get corroded and increase electrical resistance, resulting in more heat ... a viscous cycle that continued until the connector melted and the bike would die, leaving you stranded (happened to me).



I don't know if this is common to 2003 Zx6r's or not though...


That was my plan, but instead of getting rid of the whole connector just snip the one wire on both sides and hardware it in


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