I replaced the R/R with a Mosfet along with a new stator a few months back on the Superhawk. In the past few days, I smelled something burning and this morning came across a burnt connector from the stator to the bike. A quick Google search led me to find out the OEM connector is not solid and leads to this. My question mow is, do I have to replace my harness and stator or just cut where it is burnt and solder the wires?

 

Just replace the connector, best done as part of the R/R swap.....buuuut can be done later when the part fails.

Get an OEM style connector for the R/R you installed, cut the burned connector out, lengthen the wires as needed from where the old connector was to where the new R/R is mounted using your new connector

 

I ended up cutting the connector out and hardwiring, soldering, and heatshrinking the wires. The bike is up and running again, but I'm still worried about the wiring melting at the joints. Did I eliminate the possibility of this by soldering the stator to the harness?

 

The OEM plug is a known issue.. it is not sealed, and marginal in load carrying capability.

Add age and even minor corrosion... the resistance goes up... heat builds, and the plug burns.

If a good soldered joint was made and sealed... your fine,, other then not having a removable plug..

 

I just checked my splice (solder/heat shrink) , after 5 years it's still O.K. .

 

I had the same thing happen, ended up getting one through easternbeaver.com and making sure everything was nice and tight.

 

Sweet! You gave me the reassurance of this connection. If I ever feel the need for the connector again, I'll redo the wiring.

 

Jim is a great guy, I've purchased a bunch from him..

But if you do not need something only available from him,, there are stateside options.
Corsa Technic Motorsport, Motorcycle Connectors