melting plug

[doctordave]

hi guys,have a 1440 busa in the radical,the big plastic plug that connects the genny to regulator,ie 3 sets of 3 small white wires in to 3 larger wires to regulator via the plastic plug,well the plug has melted,have changed the regulator,checked earths,and used crimped spade connectors in place of plug,charging rate on dash is 14.2 volts after cold start,the 6 white wires are so hot I cant hold them between my fingers longer than 10 seconds,the 3 thick material covered wires to regulator I can hold ,anyone know if all this heat is correct ??,hope you can follow all this rambling .

[baja1969]

I would have thought that over 14V is to much its probably the regulator trying to compensate for a failing battery, it will be the current the regulator is trying to put in to the battery thats making the cables warm.

I could be wrong but I'd get the battery tested first, then look deeper and check all the connections are tight on the battery side including the starter motor connections.

hope this helps

[doctordave]

never thought of the battery,thanks .

[Simon T]

Check the inline fuse in the charging cct near the regulator. The fuse can get corroded, the increased resistance causes higher current draw and thus heat

Simon

[doctordave]

thanks simon,will check this,do you think soldering the wires would help?

[fast freddie]

I had exactly the same problem with my sr4. Hot wires blowing fuses etc, although it was showing a 14 volts charge at the battery. It turned out to be the generator had failed on one of the windings. You can download the outputs of the windings from a suzuki hyabusa workshop manual. The current should be the same from each of those 3 wires, but on my car one of them was not showing anything. After replacing the generator and the small piece of loom that had melted, everything is now ok. Hope this info helps. Good luck. Sorry bout my ramblings too!

[doctordave]

have just melted a £450 lithium battery,bu8ger,will check those wires out.