Found This..............Fixed it!

[Firehawk068]

Last night while I was installing the new oil cooler, and putting everything back together, my gaze just so happened to be drawn to that little red battery-wire connector. The one that a bunch of folks have had problems with lately.
It was right there in front of my face, so I took a good look at it.................Guess what I found?







I could not even separate the connector. It was melted right together.

I got my electrical supplies out.



I used double-shielded male/female slide connectors. Not only did I color-code them, but I installed a male and a female on each side, so there's no chance of mixing the wires up.



Glad I caught this before it left me stranded somewhere. 

[pdxfj]

Nice catch!

Keep a close eye on it though.  I ran into a similar problem on a VFR800.  They are known for voltage regulator issues.

After replacing the regulator with a Yamaha mosfet one, and replacing the already upgraded harness the problem never came back.

[Pat Conlon]

The melted connector is but a symptom.

There is a root cause. Deal with the cause and the symptom will never come back.

[ribbert]

The melted connector is but a symptom.

There is a root cause. Deal with the cause and the symptom will never come back.

Why don't the wires melt?

Noel

[TexasDave]

The melted connector is but a symptom.

There is a root cause. Deal with the cause and the symptom will never come back.

Why don't the wires melt?

Noel

Insulation on electrical wires is engineered to withstand higher heat than that nylon connector.  Dave

[balky1]

The melted connector is but a symptom.

There is a root cause. Deal with the cause and the symptom will never come back.

Why don't the wires melt?

Noel

Another reason is that heat build up occurs on connections when the connections are bad. Since the wire is continuous there is no bad connections inside it. Bad connection on a connector results in high resistance = heat build up = melting. So bad connection in a connector can be the root cause of this, nothing else. But if that repeats with new connection again then there is something other in question.