Hi I have an 07 1250 sa bandit. PROBLEM.. The electrical connection from the generator is getting hot and emitting smoke! I have tried a brand new regulator and stripped down and checked the starter motor which is okay. Checked the battery and charging circuit both okay. Checked the out put and resistance of the generator again okay. QUESTION What is causing this to get hot?

Posted by tony brook on Feb 22, 2015

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Answers :

Typically a connector that gets hot is because of a high resistance connection on the spade terminals in the connector themselves or a bad ground circuit. inspect the connector for corrosion and if all looks clean the connector can be disassembled and the female connector ends re crimped to make a tight connection on their male counterpart. To test for bad ground use a heavy jumper wire to attach battery negative to engine case as well as a second jumper wire from battery negative to the harness side of black/white wire that is attached to the original battery ground cable.
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