Cooking with plastic....connectors, that is. :)

[John Schmidt]

The regulator/rectifier on the 1200 seems to have been used in a weeny roast, as were the wires for about an inch back! Both halves look like this. One thing I noticed was the pins in both halves of the connectors were bathed in dielectric grease, a big NO-NO. It's non-conductive so you don't put it on the pins, just on the outer surface of the connector halves to help seal against the elements and dirt. And, it helps with the assembly/disassembly of the connectors....they slide easier and help seal at the same time. The same part off a 2007 or later CBR600/1000 is almost plug and play, involves a change of connectors is all. And, with a quarter century later technology it will allow charging at a lower rpm. Most will show a charge over 13v at 1k idle. There are other advantages having to do with the extra unused voltage created and how it's handled, a bit technical but very effective. Think I'll replace the connector on this one and keep is as a spare, the newer ones are at/below $30 on ebay.

[Thunderbolt]

Connections that get so hot that they melt the plastic are usually loose or not good physical connections.  As you said the dielectric grease probably should not have been there.  Some of those push connectors once they have been exercised or plugged/unplugged a few times will not make a good connection until they are replaced or at least adjusted so that they are tight.

[FloridaValkRyder]

Well John, I assume that you have started the process of wiring the 1200? Did you ever find the pictures that you took during disassembly? I know you were dreading this step in the process. Good luck and I hope it goes well.

[IamGCW]

Electronics work off the smoke, once you let it out they quit working.   

Gil

[John Schmidt]

Most owners of these older bikes just cut and solder the three stator output wires together, getting rid of the connector. It's a fix that's been in the works for years, almost from the beginning back on the '75 GL's.