Fried connector - Kawasaki Forum :: KawasakiWorld.com
 
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post #1 of 15 Old 04-06-2016, 07:40 AM Thread Starter
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Fried connector

Hi Guys,

I have a problem.
A couple of months ago i bought a nice ZX-6R from 1999 with almost 46000KM on it. I have driven it only for 3 times. When driving it last time, i visited a friend and turned the bike of for about 30-60 minutes.When i wanted to start it again, it didn't start. I bump-started it and it seemed to be running normally.
Today (4 days later) i tried to start the bike and in started normally, but i immediately noticed a tiny bit of smoke coming from the left side of the bike and after idling for less than a minute, the engine died.

I took of the seat and fueltank and found a completely melted connector as can be seen from the pictures. Is this the connector between the stator and rectifier? Could it just be a short in the connector that caused the melt? Because the wires themselves look fine. Would therefore replacing the connector or soldering the wires solve the problem? I hope it's not a problem with the rectifier or the stator....

Tips or some insight would be really appreciated
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post #2 of 15 Old 04-06-2016, 10:58 AM
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No, the stator plug is round. That just looks like an electrical short.

Any twelve people who can't get themselves out of jury duty are not my peers.

Last edited by Connman; 04-06-2016 at 11:01 AM.
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post #3 of 15 Old 04-06-2016, 11:04 AM
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It's the stator plug, but check the regulator plug also. Chances are there was a bad contact that caused a heat build up and melted it. Repair and hopefully all will be ok.

For Tech Questions Bike Model letters are more useful than saying the year, for uk owners anyway, as registration year is not always year of manufacturer model.
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post #4 of 15 Old 04-07-2016, 03:31 AM
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I had a similar incident recently with my old fireblade. I got a brand new rectifier off fleabay for £20.00 cheaper than another fry up!

I cut out the fried plug and rejoined.
I was unlucky also had to change the Stator .

Good luck :-)
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post #5 of 15 Old 04-11-2016, 01:50 AM Thread Starter
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Thanks a lot guys!

If i can't find a new connector, would hardwiring it with bullet connectors also be fine? I think i've seen that before on other forums.

Cheers,
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post #6 of 15 Old 04-11-2016, 02:38 AM
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Have a look here, but you may find them cheaper on ebay.
6.3mm 6 Way Latched White Wiring Loom Connector

Ebay something like this ?
6.3mm 6 WAY MULTI PLUG CONNECTOR TERMINAL BLOCK | eBay

For Tech Questions Bike Model letters are more useful than saying the year, for uk owners anyway, as registration year is not always year of manufacturer model.
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post #7 of 15 Old 04-11-2016, 04:28 AM Thread Starter
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With some more knowledge i opened the bike again. The connector is not from the rectifier. I checked the rectifier connector (which is 6 way whereas the fried one is 3 way) and that connector was fine.

So i think it's indeed from the stator. 3 yellow wires in a black sleeve come out of the main harnass, they go into the fried connector, and at the back end of the connector, 3 black wires in a sleeve leave and dissappear somewhere under what i guess to be the fuel pump system. But the wires and sleeve look exactly like the one coming out of the stator, so i think they're one and the same.

I will buy a 3 way connector and replace the molten one and report back to you guys.

Cheers,
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post #8 of 15 Old 04-11-2016, 04:42 AM
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Sorry, yes, get a 3 way connector. I'm sure you'll find them cheap enough on ebay.

It won't matter which yellow wire goes where.

On the zx9 its a 6 way connector, but with 5 wires in, 3 stator, neutral and cylinder head temp.

For Tech Questions Bike Model letters are more useful than saying the year, for uk owners anyway, as registration year is not always year of manufacturer model.
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post #9 of 15 Old 04-11-2016, 06:05 AM Thread Starter
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Ordering it in a currency that is not in euros delays it a bit for me.
I found this on a Dutch website:

10 Kit 1.5mm Car Boat Motorcycle Bike Truck 3 Pin Way Waterproof Electrical Wire Connector Plug 2016 ? $6.99

That should also be perfect right? The terminals look a bit different but that shouldn't matter i guess?
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post #10 of 15 Old 04-11-2016, 06:07 AM
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That might be a little small for the amount of power that might be going through it.

For Tech Questions Bike Model letters are more useful than saying the year, for uk owners anyway, as registration year is not always year of manufacturer model.
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post #11 of 15 Old 04-11-2016, 06:16 AM
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This one looks ok. 3 Way 6.0mm Latched Motorcycle Alternator Wiring Loom Connector

For Tech Questions Bike Model letters are more useful than saying the year, for uk owners anyway, as registration year is not always year of manufacturer model.
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post #12 of 15 Old 04-11-2016, 06:18 AM Thread Starter
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post #13 of 15 Old 04-11-2016, 07:04 AM
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That would work, the only reason I had not mentioned it was its to much like the rear brake light connector plug. But I can't see any one trying to connect the rear light cluster into it at the back of the engine. But you never know.

For Tech Questions Bike Model letters are more useful than saying the year, for uk owners anyway, as registration year is not always year of manufacturer model.
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post #14 of 15 Old 04-11-2016, 07:08 AM Thread Starter
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Haha yes true. To be sure i will write something on it then ;)
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post #15 of 15 Old 04-26-2016, 07:41 AM Thread Starter
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I successfully replaced the connector and now the bike starts again and seems to run just fine. I will keep a close eye on it for the coming period to see if the battery still charges and if the connector remains in good condition.

Thanks a lot for the help guys!!!
Cheers,
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  Kawasaki Forum :: KawasakiWorld.com > Kawasaki Motorcycles > ZX-6R

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