Pointy reg/rec wires getting hot

Hi there,
I've been lurking on these pages for a while now in a bid to keep my lads bike on the road, so sorry that this is my first post, and I'm asking for help!

It's an '03 pointy and I've just put a third reg/rec in it. The previous 2 were 2nd hand so just thought that they've passed their prime. After I fitted the 2nd one I had the wiring checked by a mechanic and all the readings were spot on.

Since then I've found that the 4 wires coming out of the rec (2 black/red, 2 black/white) are getting very hot after a couple of minutes, which have probably cooked the previous units.

After trawling through these boards, I have checked the connector, the green ignition barrel plug and run a couple of extra earths to the battery and frame from the rec but no difference.

All I can think now is buy another loom or get an electrician in. Any ideas please?

Thanks.... Andy

[Sid Squid]

How hot is hot? A bit warmer than you might expect is normal, but if they're properly hot the likely cause is the female connectors are dirty or not clamping the male part correctly - the resulting resistance causes heat. Clean everything carefully, and close the female connectors up a bit so they effectively hold the make part firmly.

Sorry for the late reply. They get too hot to touch eventually. I have bought a new 4-way socket from Halfords as the original looks impossible to clean properly. Both black/white wires look burnt. I would have had it done tonight if I could find my flux to solder the wire extensions in.

The moral of the day is: don't tidy your garage, you won't find anything ever again ;0)

New connector block fitted last night, wires no longer getting hot, SUCCESS!

But...
I tidied up the wiring and re-routed the extra wire from the rectifier to the positive terminal on the battery, but didn't remove the earth wire before doing so. A spark or two but nothing major. Went to take the bike out for a test run and now all I get is the neutral light on and nothing else. Have I buggered up the starter solenoid by being a bit lazy? Battery voltage is good and all fuses ok. This bike is beginning to do my head in :0/

[tj2]

Probably blown the main fuse by the starter solenoid..... is separate from other fuses.
Located under r/h (o/s) seat infill

It's a pointy, I thought the 30 amp fuse (checked ok) was under the riders seat or is there another?

[tj2]

Yeah that's the one I was on about..... derr sorry yes under the seat (its been a while since I had one)

[Sid Squid]

What "extra wire from the rectifier"?

The rectifier I bought from Wemoto has an extra wire straight to the positive on the battery.
I've mucked around with it a bit today but no joy. Swapped the starter solenoid and fitted a spare ecu, but no change. Sometimes the neutral light stays on after the ignition switch is turned off. I also noticed when I reconnected the battery and turned the ignition on, the rev counter went to 7k and then back down again?

Problem fixed!
The main earth lead connection under the rear of the fuel tank was dodgy, and I must of disturbed it when routing the extra wire to the battery.