Regulator Rectifier Connector Surprise
 

While using my bike as a model for shortening the wires on a commercial sourced RR kit (purchased for a friends VFR) I found this.

https://cimg5.ibsrv.net/gimg/www.sup...b1933c4666.jpg
I installed a Shindengen mosfet RR when I purchased the bike with 6k miles. The Eastern Beaver RR wiring kit used the stock connector, which is what is in the photo. Since the install, I have not examined the connection. Obviously a lot of resistance at the connector. The question is, why? Wondering if running heated shirt and glove liners put excessive load on the connection and has caused this.

If some of the wire strands were clipped when the wire insulation was stripped to crimp into the terminal,
it can effectivly lower the AWG of the wire and thus the current carrying capacity. That would be one cause the wire to heat up.
I'm sure the gloves and shirt definitely will contribute to the current load.

Might be due to corrosion, either on the connections pin-to-pin, at the pin crimp to the wire(s), or both. I feel this is a common occurrence on bikes. Of course, your heated accessories were a contributor if not the root cause.

The open barrel terminals were crimped on to the wire, but not installed in the connector. From memory it looked to be expertly done. The wires to the RR were scorched and the terminals were oxidized pretty badly. Wires from the stator weren't scorched, but the terminals were.

Corrosion usually isn't much of an issue here.

https://cimg9.ibsrv.net/gimg/www.sup...18185568a6.jpg

I have neither the time nor inclination to mince words. Oxidation, shmoxidation.

I just pulled the regulator off and found a totally melted connector. It was part of the voltage regulator frying the battery. With a new regulator and battery I'm hoping I'm good for awhile. You might want to put a volt meter on the battery terminals while the engine is running to see if the regulator is running hot (15-17 V). I'm on regulator # 3 now.

I would say that extra load contributed for sure. It's already a weak point. Stress it and you'll find what you showed.