Speed four nearly set on fire - SV650.org

17-05-13, 05:48 PM

So, after a week of cleaning, polishing, general tidying up of my S4, the battery died last night after a ride out.
I replaced the battery with the one off of my old SV650 SK8 and it started up fine.
Today, I had the bike running for about 10 mins while I had it plugged into tune ecu and smoke started appearing from under the fuse box

After quickly turning the bike off and disconnecting the battery, I found this

Its the wires going from the alternator, to the rectifier.

Any ideas on what caused this?? Has the rectifier failed or is it just bad luck?
Plus where can I get a replacement connector??

Cheers

17-05-13, 06:19 PM

Difficult to say but it would definitely be worth looking at the rectifier.

You may be lucky but I wouldn't hold your breath.

yorkie_chris · 18-05-13, 09:15 AM

Could be degraded connection in that place causing high resistance... voltage drop... this dissipates heat...

But, also check the reg rec just to be on the safe side.

Sid Squid · 18-05-13, 09:16 AM

This is not unusual, those wires carry the current from the alternator windings, if the spade connectors are slack the voltage passes through a reduced contact area. At higher engine speeds up there could be a hundred or more volts passing through those connectors - if they're not perfectly tight and secure getting hot is a certainty. Catching fire is very rare, usually the plastic block melts and then it doesn't charge and the battery goes flat.

I've lost count of the bikes I've fixed with exactly the same problem.

18-05-13, 10:40 AM

Thanks guys, decided to upgrade the rectifier/regulator to a FH012 R1 unit as the standard ones seem to fail a lot as it is.
Also bought a new harness and decent connectors for the rectifier to the battery and stator, should do the trick nicely and stop it trying to combust! haha

NTECUK · 18-05-13, 10:51 AM

Don't feel so bad . That's how I set my ZX6 smoking too.
Mine was road salt build up .Luckily yours was at home.

18-05-13, 10:57 AM

Quote:

Originally Posted by NTECUK

Don't feel so bad . That's how I set my ZX6 smoking too.
Mine was road salt build up .Luckily yours was at home.

Very true! Although I did cack myself thinking the tank was leaking again!!

17-05-13, 05:48 PM	#1
Mikey360 Guest Posts: n/a	Speed four nearly set on fire So, after a week of cleaning, polishing, general tidying up of my S4, the battery died last night after a ride out. I replaced the battery with the one off of my old SV650 SK8 and it started up fine. Today, I had the bike running for about 10 mins while I had it plugged into tune ecu and smoke started appearing from under the fuse box After quickly turning the bike off and disconnecting the battery, I found this Its the wires going from the alternator, to the rectifier. Any ideas on what caused this?? Has the rectifier failed or is it just bad luck? Plus where can I get a replacement connector?? Cheers

17-05-13, 06:19 PM	#2
Spank86 Guest Posts: n/a	Re: Speed four nearly set on fire Difficult to say but it would definitely be worth looking at the rectifier. You may be lucky but I wouldn't hold your breath.

18-05-13, 09:15 AM	#3
yorkie_chris Noisy Git Mega Poster Join Date: Apr 2007 Location: Halifax/Leeds Posts: 26,645	Re: Speed four nearly set on fire Could be degraded connection in that place causing high resistance... voltage drop... this dissipates heat... But, also check the reg rec just to be on the safe side. __________________ Currently Ex Biker Now rebuilding a 63' fishing trawler as a dive boat

18-05-13, 09:16 AM	#4
Sid Squid No, I don't lend tools. Mega Poster Join Date: Jul 2003 Location: Skunk Works, Nth London Posts: 8,680	Re: Speed four nearly set on fire This is not unusual, those wires carry the current from the alternator windings, if the spade connectors are slack the voltage passes through a reduced contact area. At higher engine speeds up there could be a hundred or more volts passing through those connectors - if they're not perfectly tight and secure getting hot is a certainty. Catching fire is very rare, usually the plastic block melts and then it doesn't charge and the battery goes flat. I've lost count of the bikes I've fixed with exactly the same problem. __________________ If an SV650 has a flat tyre in the forest and no-one is there to blow it up, how long will it be 'til someone posts that the reg/rec is duff and the world will end unless a CBR unit is fitted? A little bit of knowledge = a dangerous thing. "a deathless anthem of nuclear-strength romantic angst"

18-05-13, 10:40 AM	#5
Mikey360 Guest Posts: n/a	Re: Speed four nearly set on fire Thanks guys, decided to upgrade the rectifier/regulator to a FH012 R1 unit as the standard ones seem to fail a lot as it is. Also bought a new harness and decent connectors for the rectifier to the battery and stator, should do the trick nicely and stop it trying to combust! haha

18-05-13, 10:51 AM	#6
NTECUK Member Mega Poster Join Date: Apr 2011 Location: essex Posts: 5,314	Re: Speed four nearly set on fire Don't feel so bad . That's how I set my ZX6 smoking too. Mine was road salt build up .Luckily yours was at home. __________________ Raisin cookies that look like chocolate chip cookies are the reason I have trust issues.

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