Hot wire

[Garybear]

I ride an 87 Aspencade and I really enjoy the digital dash. This spring I messed up and left the key on to the first position and killed my battery. Now I have a new glassmat from O’Riley’s in and the bike is running great. I’ve started taking the key out when parked so that should fix the battery problem but now I’ve noticed the a hot wire smell (melting insulation) when riding. The battery cables are cool to the touch and the battery is fully charged when I stop. It isn’t discharging when off. I hate the “wait and see what fails” when I’m away from home. I do mostly short two or three hour rides near home but even then I don’t want trouble on the road. Any ideas?

[Rambozo]

Look and see if you have picked up something on the exhaust.

[Garybear]

That’s a good idea. I will check it tomorrow.

[Rambozo]

I had a customer who was sure her engine was blown up from all the smoke and smell, but she had just picked up a big trash bag melted on her exhaust.

[Garybear]

That sounds like a smell not soon forgotten. Easiest fix you’ve done in a while I suspect.

[Track T 2411]

Check the three yellow wires and connector next to the battery. The connector is a common failure point...

[Garybear]

I will check them. What do they go to?

[Track T 2411]

They are the wiring for the stator, the bike's charging system. The connector by the battery often begins to overheat due to corrosion, and if left unattended can lead to stator failure.

[Garybear]

Thanks for the info. A poor connection could definitely generate heat. I will check them and the status of the batteries charge.