Honda Shadow VT-700/750 '83 & 84 Whats with the rectifi

[dieselhauler]

rectifier wiring melt down. All my shadows have a serious melt down problem at the wire connector. Three yellow wires from the rectifier going over to the alternator melt down at the plastic connector. Charging is not affected.

[Evil Twin Brother]

I have a 85 Goldwing, I have the same problem, I am going to cut out the connector and splice the wires, I would advise using heat shrink on the splices, thats my plan.

[dieselhauler]

That will Not resolve the melt down..the wires are still burning hot as if there is a direct short which in the end may burn out the stator or something worse. I have already alleviated the connector and removed it from the harness holder ( in fear of a grounding short). It's hard wired now. It's charging at 15 amps, if it charges over 15.5 amps, it will fry the battery. Both bikes have the same problems.

[Evil Twin Brother]

If the wires are hot from the alternator then your rectifier/regulator may be bad or something is loading the rectifier down. I never had the problem you are describing. Are you measuring 15 volts at the battery when the bike is at idle? Check all your ground wires not just the battery ground.

[dieselhauler]

The wires from the alternator are not hot. The amps are uniformed with minimal variation. (.05 variations) I did an external short test..no short.
I did an integral short test using the integral ground, it's ok. Volts were measured both at the battery and the hot wire of the alternator.
If the rectifier is being overloaded the short would be found in the alternator. Otherwise it would be the rectifier. If the problem is not resolved, then I'm just throwing money away at parts. I have 10,000 miles on this bike, no reason for this wear. I am wondering if the problem is remote, I'm beat. Thanks for trying. I'm going to review my schematic to see where the pulsor comes in from the alternator.