Re: Charging fault?
 

Trim back the wires to 'good' cable before recrimping, might mean taking a good inch off each one

Re: Charging fault?
 

It probably will be, if it's been working at all - the system has been functioning with one third the charge rate it should have, this suggests the components are OK, and the wiring fault you've found is the culprit.
This is a surprisingly common area of wiring deterioration, the voltage carried by those connectors can rise to very high numbers, (at 5000 rpm there should be approximately 70V AC at that point in the system), unsurprisingly any slackness in the connectors will very often manifest itself as arcing and burning - precisely what has happened on your bike. Standard wiring is no stranger to this problem, and your bike still has the standard female connector which is very likely the cause. (see below)
I'll be brave and suggest that you very probably don't need one, fix the connections and there's plenty of reason for optimism.

Replace the connectors, the greatest likelihood is that those ones fitted, (which are fine if fitted correctly), are simply slack in their female counterpart, this doesn't mean they've been fitted wrongly. When you fit new connectors ensure that they are firm when inserted, if not then gently close the female part with pliers until the male section is tightly held. This may mean removing the female section from the block - if that's required I can give you details of how it's done.

Re: Charging fault?
 

Ok, guys,
I followed what to do and ended up with this connection.
Thanks sid for the tip, I had to 'help' the top connector to close to get a really good fit.

http://farm3.static.flickr.com/2680/...59b65d4c_o.jpg
http://farm5.static.flickr.com/4057/...377c0e38_o.jpg

The results of the voltage test are as follows

Ignition off - 13.43V
Ignition On - 13.34V
Engine on (1300ish rpm) - 14.24V
Engine on Lights On - 13.77V
Engine @ 5000rpm - 14.07V
Engine @ 5000rpm with lights on - 13.18V

Are these figures ok? The Engine on @5000rpm with lights seems a bit lower than the manual says it should be (13.5V)

Re: Charging fault?
 

I don't have a manual to hand with the correct figures so I can't help with that.

My only issue is that those connectors still aren't the best, still should do you for a while though (and definitely better than the previous ones!)

Druid

Re: Charging fault?
 

Agree with you about the connectors but until I get some funds together I hope they last.

As a note, the battery was just taken off the charger when I did those test, gonna take the bike for a spin later and will post new test results later

Re: Charging fault?
 

I hate that set up.
I know all the plastic surround does it hold the spade connectors in place and seal them a bit better but still it really should be done with some proper connectors.

Where are you based spanner? As I said earlier I've not long since done a reg/rec replacement on my curvy and I've got some some connectors left over.

Re: Charging fault?
 

I'm from Ireland so a fair bit away from you.

If the voltages are correct and all my electrical woes were from this ugly bit of wiring then I'll def splash out on some proper connectors.

btw what are the proper connectors?

Its amazing that I spend all my hard earned on a repairs in a shop when a couple of days talking to people in a different country has proved to be about 1000 times more useful

Re: Charging fault?
 

Those connectors are fine - as long as they stay firm and don't slacken off, which is true of all connectors, certainly the standard ones and all the others you'll find too.
Those figures you give aren't the very finest, although many bikes give similar figures and work just fine, but the proof of the pudding very much is in the eating. Use the bike - see what happens.

Re: Charging fault?
 

Hi, to improve on conductivity between wires and connectors, IF available run some solder down the wires/connectors with a soldering iron before moisture again causes ingress?
Additionally wrap the whole plug/wire assembly in Self Amalgamating Tape which is a very stretchy adhesive rubberised tape that creates a very good seal if made cleanly.
JOHN

Re: Charging fault?
 

Ones like from here
http://www.vehicle-wiring-products.e...e/homepage.php

Druid