How to Hardwire a Motorcycle Stator to Regulator Rectifier

Multiple motorcycle makes and models experience problems with burnt or melted stator connectors and wires. Ducati, Harley-Davidson, Aprilia, Honda, Suzuki, Kawasaki, Triumph and others, all experience this issue. Oftentimes, those who've experienced this problem share a short, succinct piece of advice: 'Just hard-wire it!'

I have seen this advice on many forums, but when I searched for a video showing 'How to hardwire a motorcycle stator to a regulator-rectifier,' I could not find many useful videos. So this is my version of hardwiring your motorcycle stator!

My problem surfaced likely because of an oil wicking problem in my stator wires (I'm planning a video to cover this unusual circumstance, as well). However, in my opinion most instances of a burnt or melted stator connector and/or wires, is due to poor preventative maintenance. Dirt, oil, grime, salt, sand, moisture and oxidation all increase resistance in the connector, and this resistance equals heat--and a lot of it. If this connector is overlooked during cleaning time it will be just a matter of time before the heat starts to cook things up.

While hard-wiring eliminates the connector 'hot spot,' there are two drawbacks: 1) There's no way to test the stator and/or reg-rec unless you re-cut the wires; and 2) On my Ducati, the reg-rec has to be removed every time the alternator-side crankcase cover is removed. This isn't a huge deal: The battery has to be disconnected and the ECU has to be loosened and moved out of the way before the two bolts securing the regulator/rectifier can be accessed.

Finally, I used sealed crimp connectors with an extra layer of heat shrink and a full wrap of silicone tape for added protection. There are many other options that would work very well for this project; Solder (for those who know how to solder properly), non-insulated butt connectors and solder (with heat shrink), and a variety of other methods.

I hope you enjoy the video, and Good Luck with your repairs!

Associate Links to items used in this repair:

Power Phase Butt Connector 16-14 AWG (Sealed Crimp Connector) Part #58590 https://goo.gl/PJ2aJu

Power Phase Crimping & Wire Stripping Tool Part #0710609 https://goo.gl/PJ2aJu

You can purchase these items through eBay (some times you can find great deals there), or go through Fastenal (online or local store if one is available near you).

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