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Electrical Problems - Harness Melted

Old 04-15-2015, 09:25 AM
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Electrical Problems - Harness Melted

Just noticed the carnage in attached picture last night but everything (for the most part) is working fine.

Background (useful and otherwise):

98' Superhawk 40k+

Last year I blew the main 40 amp fuse and melted my R/R, I replaced fuse, Stator, R/R and battery (it was not holding charge). The bike ran great all spring/summer except my turn signals began to slowly work slower and slower. Then this last winter someone tried to start my bike with a screwdriver and destroyed my ignition switch. I threw the battery on a trickle and let it be.

Just last week I swapped the ignition switch, the key set and rode all weekend. Everything was great except my right turn signal (front, back and dash) were completely dead. Monday I noticed the battery had a little trouble starting and was concerned it wasn't holding/getting charged but rode anyways. On my way home I got in a pretty good rain and saw what looked like smoke rather than steam and smelled a bit like burning.
I got home, took of the rear fairing and inspected the signal relay (when engaging non-functional right turn signal I smelled a light burning plastic smell), checked fuses, got the amp meter to check battery charging and then found this (attached pic)

Anyone have suggestions, help, advice? Looking through posts maybe I cut, solder and shrink wrap what is left or maybe I need a new harness. Just don't want this to happen again.....always trouble in the spring.
Attached Thumbnails Electrical Problems - Harness Melted-fullsizerender.jpg  
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Old 04-15-2015, 10:08 AM
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Looks like you'll need to replace loom, charging system wiring and some...

Sounds like your first electrical meltdown was caused by R/R imploding. I highly recommend you get A MOSFET FH R/R (along with a new battery) - Search here for workshop thread on how this is signficantly better than the standard shunting OEM R/R.

When you say 40 amp fuse did you mean 30 amp as that is what should be fitted.

Last edited by Wicky; 04-15-2015 at 10:10 AM.
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Old 04-15-2015, 10:27 AM
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Sorry, yes 30 amp not 40.

Thanks for the tip on the R/R I may look into it after all this. I do currently have an aftermarket heavy duty R/R on the bike that is still under warranty. The wiring on the R/R end looks fine and so does the R/R. Was going to run through diagnostics but is it naive to hope my R/R and battery are still good?

Thanks for getting back to me!
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Old 04-15-2015, 11:06 AM
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The plug failed as many do, they are not a modern sealed type, they get old, corroded and then high resistance,,,, melting soon after.

A Kit like this
Home

or make one up yourself with a used R/R from an R1

that bypasses the melted plug you have now.(well really you take it out of the system as well)

And then check the wires and connections near buy for damage, repair as needed.

Last edited by E.Marquez; 04-15-2015 at 11:15 AM.
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Old 04-15-2015, 11:45 AM
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What made you change the stator? Was that your idea or was there visible damage? That is usually something a shop likes to tack on if your RR goes.

Those plugs are at the seat front right? You can (should) replace them. They can be bought at Molex ( View List .093&offset=80&npp=20&sType=n&fs=&channel=Products &autoNav=2&path=cHome%23%23-1%23%23-1%7E%7Ef3%7C%7C576972652d746f2d57697265%7E%7EncCRI MPHOUSINGS%23%230%23%2346&Itemlist=

Be sure to use the mofset Regulator if you haven't already. That is the root of the problem. Search mofset on here.
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Old 04-15-2015, 12:32 PM
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Replaced the stator and the R/R at the same time as suggested by the previous owner.

So now I have what looks to be a fine intact electrosport R/R but as I read I'm learning electrosport sells crap stuff. Would you just trash the R/R on there for a MOSFET? Leave shitty electrosport stator?

So much money wasted on shitty parts.......

Thanks for the comments.
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Old 04-15-2015, 12:41 PM
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Old 04-15-2015, 03:43 PM
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For the future, you'll save a ton of cash if you save your money for stuff that actually needs replacing.

You can get a mofset R1 regulator on fleabay cheap. As I recently posted I even stock a spare to keep me riding.

Go to eastern beaver for a high quality connector R/R Connectors

I would not at all leave that RR on the bike. It has already begun to ruin your life and things will not improve.

This would do it for even cheaper http://www.ebay.com/itm/Regulator-Co...fb640c&vxp=mtr

Heck the whole harness is within reach http://www.ebay.com/itm/00-Honda-Sup...4376c3&vxp=mtr

Last edited by smokinjoe73; 04-15-2015 at 03:49 PM.
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Old 04-20-2015, 09:43 AM
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Thanks for all the input.

So I'm going to upgrade to MOSFET based on all the encouragement.

Does anyone have any comments/advice on splicing in new box connectors for the stator and fuel sensor vs replacing the whole harness?

The melting looks like it started on the stator side of the connection.

I think the stator is shot my readings are .3 on all wires

My R/R is reading:
0 0 0
444 447 437
0 0 0
450 433 466

Last edited by NewGuy; 04-20-2015 at 09:45 AM.
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Old 04-20-2015, 09:59 AM
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I would replace those connectors over the whole harness. The whole harness is a big pia job. The trick is to see if you have enough wire to splice into. Honda tend to leave precious little slack so the wire don't go rogue.
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