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Discussion Starter #1 (Edited)
Rectifier Regulator Melted to Harness

Hey,

Just bought a 2005 Ninja 500 last Fri. Have ridden it a total of 30ish minutes. The bike completely died after 10 minutes. Had the battery tested, it was completely dead. Decided to replace it with a lithium battery to get some longevity out of it. The battery was completely charged when I installed it into the bike. The bike died completely died after 10 minutes of riding. Checked the battery, it was dead again.

After a few hours of tinkering, I realized it's probably the charging system. Battery wasn't being charged while riding. Got a multimeter, checked the stator and it seemed to be reading normal.

The rectifier regulator on the other hand was melted. Had to pry it apart from the plastic harness. Multimeter readings on the R/R was 0.00

My question is, what is the best way to fix this problem. I know I probably need to buy a R/R (which has a female harness connector) but I'm wondering:

1. What is the male connector harness that plugs into the R/R harness?

2.What does it connect to? I followed the wires and they are covered in electrical tape and appear to lead underneath the tank, but I'm not sure. I was thinking it was connected to the stator but I can't tell.

Also, the alternator/stator was replaced by the previous owner a year and a half ago, the R/R was not. Some people have told me they should be replaced at the same time.

Any help is appreciated! I'm new here and new to bikes - willing to learn as much as possible!
 

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Wow, an old thread here. Anyways, once the connector terminals corrode, resistance builds...heat...then more corrosion...more heat...eventual wiring damage occurs. The original EX RR's tend to run very hot (shunt) as well.

Fixes/upgrades do exist.
 
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