hey guys...once again sorry i know it's a zx6r question istead of gs500 but kawiforums really doesn't help...

i'm sure someone can help me here...


ok so i tore apart my 98 zx6r and found a connector that was melted...there were 3 wires going to the stator and into main wiring harness and with the manual i traced that the other end went into the regulator/fectifier....well i don't know why the connector got burnt...i put the bike back together and those wires get so hot it melts the electrical tape off of them...i may have switched the wires around and they may not be connected right because the connectors are melted...

my question is with a miltimeter how can i find out which wire connects where? so there are just 3 wires that have to connect to one another and i need to know which connects to which...also, what could have caused the connector to melt like that? i had no problems with the bike..it always started without a problem and i had no wiring problems untill i found this problem

thanks

OK you will proberly find that your stator has burnt out, due to a faulty regulator/rectifer, What happens is the regulator fails and the alternater , being unreguled just goes crazy producing much higher voltages than your wiring is cabale of carrying and things begin to melt.  Time to spend some money, you will proberly require a new regulator and proberly a new stator in this is fried also.

I agree with Rob, the stator winding is faulty, probably shorted between turns or breaking down to ground. As a result its putting out excess current/voltage and overheating. The generator, rectifier and regulator all have a bearing on each other and failure of one of these will almost certainly cause problems with the others. The service manual for the Zx6 will quote the correct test procedure for the suspect parts and give you all the information you need,  I suggest you try to beg/borrow/steal one.

This outfit will sell you the parts you need.

http://www.electrosport.com/index2.html

Starwalt? its a sparky issue, any comments?

Welcome back, Nick!
Look at  http://www.electrosport.com/Images/fault_finding.pdf
...especially the test on page 4: resistance from any of the three yellow wires to any of the other 3 yellow wires should be low (e.g. 0.5 to 2 ohms); and resistance from each yellow wire to the frame should be high, 100 ohms or more.

But do the other tests as well, because even if the stator is shorted or burned, you still want to find out why (bad regulator?).  There's a reason that the stator tests are on page 4!

Thanks guys...i will test the stator and regulator today...then i can figure out which one is fautly and replace it

Thanks again

well i tested the stator today and it's good..mine is 55v ac @4000 rpm..spec is 43-57
i've tried testing the regulator but i got nowhere...i think that's the problem so i'm gonna order a new one and see what happens

as for the 3 wires going from the stator...they are all back and going into 3 all yellow wires...i don't know which way they connect because the plug got melted...i was told that they are all positive and it doesn't matter which way i connect the wires but that doesn't sound right to me?

Quote from: GRU on March 04, 2006, 05:20:46 PM
..........i was told that they are all positive and it doesn't matter which way i connect the wires but that doesn't sound right to me?

I think you were told correct.

The R/R diode ckts for each phase are in parallel with each other. Being in parallel means that they each have common positive and negative connections.  They each end up at the same place in the ckt.  Therefore it doesn't matter which is which.

Also, if it  mattered, I would think the color of the three wires at the R/R would be different, not all the same (yellow).

yes that makes sense...thanks 

just one more question...would a faulty regulator/rectifier cause wires to burn? beacuse like i said before i tested the stator and it's within spec so the only other thing that could be wrong is the regulator right?

The generator delivers a 3 phase AC output, with it being AC there is no positive or negative so interchanging the leads will not matter. I am still suspicious of the stator though . A faulty regulator also causes under/overcharging problems with the battery and dim or bright and constantly blowing bulbs, this being due to it letting too much or not enough voltage into the bikes electrical system. Have you had any problems like this?? Its also possible that the generator winding only develops the fault when it warms up and is under heavy load. Is the wiring from the generator to the regulator sound, with no open cicuits or shorts?

i've never had any electrical problems with the bike...the only thing that happened was a burnt tach light but that's it...the wiring harness looks really good and has no shorts

Quote from: GRU on March 03, 2006, 06:27:00 PM...ok so i tore apart my 98 zx6r and found a connector that was melted...there were 3 wires going....well i don't know why the connector got burnt...i put the bike back together and those wires get so hot it melts the electrical tape off of them...

After reading the previous posts, you may well be onto the problem. Did you only have one connector melted? If so, that would seem odd unless there were a path from the high current source (battery) to the stator to ground (earth).
Something like this...
Battery---->connector>----Stator-----Ground (earth).

This would be BAD.

Was the bike running when the wires got hot?
If you had a shorted turn in the stator, your output would be reduced (which it doesn't seem to be after you have checked it).

The normal arrangement would be:

[R/R diode]------->connector>------Stator 1
[R/R diode]------->connector>------Stator 2
[R/R diode]------->connector>------Stator 3

Regardless, the high failure item here is the R/R and probably the culprit.

Make sure the connections are clean and tight. Any resistance due to loose/dirty connections will create heat at the bad connection point.

There is only one connector that got melted..that was the one going from the stator to the main wiring harness...that's all that got melted and yes the wires get hot when the big is running