The plug from the Reg/rec was melted and had a hole in the side, one of the terminals was black. The termials didnt appear to be touching though. I have since replaced them both on both ends after swapping the rec. They dont get hot during operation.
The Ignition switch connection with the Red, Brown, And Blue wires was also melted. I cut some of the wire back and installed new termials on the red and brown wire. The blue wire and terminal seem fine.
Igniton switch is free of corrosion btw.
Okay now to my issue.
The Smaller ground wire get's warm at the connection plug along with the wires.
The red and brown wires seem to get hot when i have the headlights hooked up. I've let the bike idle to the point of the fan comming on, the wires seem to get pretty hot. This issue is much more noticable with the headlights hooked up.
This heating is most noticable with the headlights on.
What i've done-
Put di-electric grease on every connection i can.
Checked ground on engine, it was clean.
Taken wire harness apart and searched for broken, torn wires, not finding any. All the factory splices seem ok meaning not corroded.
Can't seem to find any shorts, in testing the red and brown wires on the ign circuit.
Tested the Headlight harness and everything seems to be ok too.
Can anyone tell me where and what else to look for as I am at my limits.
Could it be the connectors i used? I used a "heavy duty" type connector on the ignition wires. If not what should i run?
Would it possible i didnt trim the burned wire back far enough?
Could a relay be the problem?
. They might ship them tomorrow, maybe have them by next week