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6th gen wont start--Melted connector


megatronousprime

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So I already changed the main fuse holder to a good marine grade holder....but I didn't do anything to the smaller connector on the bottom.MELTED2.thumb.JPG.dba3e4f4db97454afdcddd2b24468414.JPG

My bike would not start yesterday after a short ride --I looked under the seat and found that the smeller connector that's connected to the 30AMP Main Fuse holder is melted...I killed the battery trying to crank the bike over...

Can anyone help? How can I get the bike to crank over? do I cut out this connector and sodder wire to wire? please help.

MELTED.jpg

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  • Member Contributer

Connectors get hot/melt due to corrosion. The corrosion reduces the surface contact between the connectors and that increases the resistance, if you put current through high resistance you get lots of heat (and weak current reaching the starter). So you need to at the least clean out the connector, but best of all would be to cut it out, trim the wires back to an unburnt section and splice in some new wire, either with a new connector or directly soldered. 

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  • 2 weeks later...
  • Member Contributer

My Story...

What causes melted connections is indeed corrosion that builds up between the
quick disconnect pins generating resistance enough to melt the plastic
and insulation and it may go as far to cause a fire...

 

As the RC45 Club's tech advisor I received this urgent photo and a
request as to the reason why fire almost claimed this members RC45 ...

TcvPjD3.jpg

 

Story goes that Bob and Pam Solloway of Coventry UK... a couple of RC
freaks... were on the way to Misano WSB... Pam's RC45 caught fire
while stopped at a light... the flames were beat back by bottle water
from a passing van... they were lucky the incident did not happen out
in the middle of nowhere for it would have spread rapidly to the fuel
lines and then the tank... nothing is worst as watching bike
flambeau...

 

First call was to check the alternator quick disconnect at the
transformer rectifier... I was positive that the QD had suffered
enough resistance to heat and melt the insulation on the wires... the
wires got enough to start a fire which all most consumed her prize...
I seen this problem before...

 

As I prepared my case for Pam I pulled the seat cowl off my RC45 to
send her a pic of the quick disconnect in question... Mercy was I ever
in for a shock... my quick disconnect was bad and about to turn my
bike into a crispy critter...

TUwDVzA.jpg

 

Apparently corrosion builds up between the quick disconnect pins
generating resistance enough to melt the plastic and insulation...

Cleaning the pins with a wire brush and coating them in dielectric
grease can prevent this danger from becoming a problem...

 

My quick disconnect was toast... I decided to cut and solder the wires
directly and seal with heat shrink tubing...

I've solder the wires directly to eliminate the possibility of fire...

 

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