The vire that comes out from engine connects to a three way connector at the site of battery. it always get melted for abot a month period. prior to that i put a extra swith to switch off the head lamp. and by mistake i forgot to turn it on when i ride da bike since then only i got tyhis problem. the other part of that three way connecter is connected to cdi unit i think. cdi unit has2 plugs to connect. one i think rectifirs. those connected to melting vires. how can i check this .?
Imnot clear as to what exactly your saying but if you have a wire melting it is either you have a short which if you did it would be blowing fuses, most likely you have an excess of amperage going thru this wire, you should definitely let someone at a dealer look at this.
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The yellow wires can go in any order (its does not matter as long as the wires are one yellow wire to one yellow wire. They melted most likely because the connector was corroded (had a bad connection) or the charging system has an issue. Put a new connector on it. Run the engine @ about 2500rpm for about 5 minutes, then grab the connector with your hand to see if it is hot to your touch. If the connector is not hot then most likely the charging system is ok and if the connector is hot, then the charging system has something else wrong in it.
Locate the three wires (usually yellow) that come from the stator to the regulator/rectifier. They should be on a connector near the battery. Disconnect the wires and check the resistance of the stator leads between each other (3 checks) and from each lead to ground. There should be approximately equal resistance from lead to lead and no continuity to ground. Also check for AC voltage between each lead with the engine running. These readings should be approximately equal and should increase when throttle is applied to about 60-90ACV. If the stator resistance and output check out, your regulator/rectifier is bad. Unfortunately stator failure is common on these models and the engine must be removed for replacement. Another common problem is that the connector itself will corrode/melt. Honda sells a replacement lead kit that you can install, or you can just hardwire the stator to the reg/rect.
The heating up would be normal as relatively, high current is passing through these wires/terminals not only to charge the battery but to power the electrics of the bike. If the regulator is working correctly, it would soon dwindle down since presumably the battery has been charged. Almost always, the connector used is not plastic but phenolic or epoxy based due to this very reason. Another possible reason for excessive heat is that the terminals are not tighly fitted to its counterpart connector. A loose connector would result in a slight voltage drop but high current accross the connection.
check the stator conetion that is next to battery(three yellow wires and prob.one melted three wire gang plug). if not melted check all 3 wires to ground there should be no continuity.then check all 3 wires for 1-5ohms of res. if you have cont. to ground stator must be replaced. if stator checks good repair wires if melted and recheck dc output at battery. if still not charging at 14.DC volts check reqtifier/regulator. under your glove box to the left side.
email me then i could send u the wiring diagram, email@example.com. i have a similar problem the connector from the altenator melted done all the tests on the altenator but could not find any prob. but the altenator still not charging the battery.