Melt down!

[TheSilencer]

I own a '81 GS450 and I've recently started rebuilding it and getting it running. Its been running for about a month or so now and I've been riding it a bit on the weekends and now and then.

The tail light stopped working so I replaced the globe but to no avail. started tracing the wiring to try find a bad connection. Removed the seat to access the wiring below the seat. Then I noticed a thin line of smoke rising!

Turns out one of the 3 wires coming straight out of the engine block has completely melted down. There are quite a number of wires coming out of the block but these 3 are grouped together and the one is getting VERY hot. The insulation has started melting away completely.
Id like to know what the wire is attached to inside the engine and why its getting so hot?
Its melting the insulation sort of midway through the wire - not on either end. (This mean anything?)

Thanks!

[Nessism]

Your stator shorted out. To fix it check the following link... http://www.thegsresources.com/garage/gs_statorfacts.htm

[TheSilencer]

Thanks for the reply! After doing some research I discovered that the 3 wires coming up out of the engine are coming from the stator. I therefore read through the stator papers and did the tests.

Turns out the (+) RR to (+) Battery connection wasn't all that good. (Make sense) I've made GOOD (+)RR - (+)Bat and good (-)RR - Ground connections. Hopefully that will sort it out.

According to the tests listed in the Stator papers there isn't anything else wrong. Stator seems to be OK and the Rectifier seems to be OK with all checks.

Ill post any further problems I may have.

Thanks again for the help! Both to Nessism and to theGSResources in general for a GREAT site!

[posplayr]

Thanks for the reply! After doing some research I discovered that the 3 wires coming up out of the engine are coming from the stator. I therefore read through the stator papers and did the tests.

Turns out the (+) RR to (+) Battery connection wasn't all that good. (Make sense) I've made GOOD (+)RR - (+)Bat and good (-)RR - Ground connections. Hopefully that will sort it out.

According to the tests listed in the Stator papers there isn't anything else wrong. Stator seems to be OK and the Rectifier seems to be OK with all checks.

Ill post any further problems I may have.

Thanks again for the help! Both to Nessism and to theGSResources in general for a GREAT site!

None of the stator pages test will detect poor stator wire connections. If you still have bullets on them get rid of them.

See the link in my signature for "GS Charging System Health". There are several preventative measures to take re: grounding and connections. Not sure if you followed the old fault isolation diagram of a revised one.