What NEEDS to be done to 6th gen electrical system

I had all of the recall work done to my bike this fall but I also wanted to do what is necesssary to make my bike reliable. I know there are a lot of links on here so if someone culd direct me to what still needs to be done I would appreciate it to help narrow down the search. Thanks.

After I had the recall done the two issues that came up on my '02 was the 30 amp fuse next to the battery overheating and the plug between alternator and rectifier/regulator heating up. As these items corrode they build up resistance and heat up when current is high. A weak battery will draw more current through the 30 amp fuse.

I replaced the fuse holder with one of these
http://www.amazon.co...e/dp/B003EEV1YS

I replaced the alternator plug with one of these
http://www.wiremybik...products_id=693

I had no problem for 5 years until 48k miles. Now at 87k miles with these fixes all is working.

[image: View Post]Bad Boy, on 04 January 2011 - 01:09 PM, said:

After I had the recall done the two issues that came up on my '02 was the 30 amp fuse next to the battery overheating and the plug between alternator and rectifier/regulator heating up. As these items corrode they build up resistance and heat up when current is high. A weak battery will draw more current through the 30 amp fuse.

I replaced the fuse holder with one of these
http://www.amazon.co...e/dp/B003EEV1YS

I replaced the alternator plug with one of these
http://www.wiremybik...products_id=693

I had no problem for 5 years until 48k miles. Now at 87k miles with these fixes all is working.



plus one! also make sure that ALL electrical connections are clean and covered in diaelectric grease.
you might want to look into a vfrness, and there is a new style rr out there. its not the shunt style/ or mosfet style, its a totally new design. i forgot what its called. i havent heard of anyone trying it out yet though...

oh yeah here it is lol:

http://www.vfrdiscus...7-compufire-rr/

[image: View Post]danmurphymn, on 04 January 2011 - 11:54 AM, said:

if someone culd direct me to what still needs to be done I would appreciate it to help narrow down the search. Thanks.


Don't know of a single link that can answer your question, you have to filter through the various fixes and try what seems worthwhile to you.


My personal opinion of what you NEED for reliable travel:

-- regular inspection/cleaning of electrical connections, especially stator to RR, starter relay, and main fuses A and B.
-- a voltage monitor. If the bike suddenly dies, it's nice to be able to rule out over/under charging right away.
-- basic electrical knowledge of VFR and the common issues it has.

Here are a few of the additional steps I have taken to have a reasonable level of confidence for travelling solo in the great wide open.

-- dedicated voltage monitor wire to RR
-- blue connector ground jumper
-- put together an electrics kit consisting of:
--- circuit tester
--- length of 14 gauge wire
--- variety of lugs, connectors, butt splices
--- tape, heat shrink, spiral wrap
--- pre-built harness for Main fuse A and B replacement

[image: Posted Image]

I took all of the preceding actions after my '07 died mid-corner in local heavy traffic. I was able to coast off the road and got a quick fix in thanks to the info available on this forum. After implementing the aforementioned fixes I was able complete 2 multi-state trips later in the summer with zero electrical issues and no problems of any kind.

Link to thread re: my electrical failure
http://www.vfrdiscus...__1#entry705434

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