Went out with the old girl for a ride this morning and I swore I could smell something was off, I put it down to the new friction plates but once back in the garage I quickly sniffed (pun intended) out the problem....there's no mistaking the smell of electrical burn. Things on the top of my mind: How to replace the plug. I'm guessing this isn't a separate cable from the alternator so...replace the whole thing or is it worth considering rewiring? How the f*** did this happen? I'm running a top of the range MOSFET R/R from RM STATOR which should be better than OEM, could this have been the culprit?
Commiserations, it only takes a bit of light corrosion on the terminals for that connector to offer some resistance and it can just gradually rise in temperature until the melting begins. I've often said people ought to check to see if their alternator and regulator connectors are getting hot, they are often warm at the best of times.
The RR is a specific Ducati one from Moto Electrical in the UK: https://www.motoelectrical.co.uk/ty...00-650-955-1050-ducati-749-848-999-1998-2013/
I agree with Sev. A few years ago I converted my old M900 to a later Ducati Shindengen unit from I believe a Multistrada, and used a set of cables off Ebay originally meant to convert a Triumph I think. The issue on an older bike is the lack of a charge light output which I got around on the M900 with a charge monitor LED. But on the 999 that's not an issue. I have a Shindengen and leads in my garage ready to fit to whichever of my bikes Reg/Recs gives up first. Don't be tempted by an Electrex world unit. I had one last no time at all, then the replacement did this:
Anyone have any experience with these? Either this or the crimp connectors with heat shrink wrap on the ends, similar to the ones in this video which details a direct connection from the alternator to the R/R on an 848:
That's right, problem since birth, sometimes you can use a method of splitting the wires into strands without welding them together. Of course, the oil flowing through the three wires can cause condensation and cause serious fires. And it's worse than you think. But everything has a solution, always welcome.
Another afternoon of strong words with the battery box and hey presto, alternator wiring has been directly connected to the MOSFET R/R. I'm not 100% happy with the placement of the R/R as its right under the LHS fairing, although this particular R/R barely heats up at all. Voltage measured on the dash is much more in line with spec now that its been wired up directly, I think my thread here (https://www.ducatiforum.co.uk/threads/average-vbatt-reading.83289/) was an early indicator of resistance building up on that plug. I'm now getting 14.2v under light (2-3k rpm) load. I might be tempted to move the R/R over to the RHS of the bike but time/materials being what it is at the moment, I went with the simpler option. Can anyone recommend a decent 3pin plug (preferably >= IP65) that can handle the current from the alternator? Even better, is there an alternative to the silly battery box on the 999 ?
Best candidate for a 3pin plug I've found at the local electronics shop is: Unfortunately not sealed but its for 12AWG wiring and rated to 30A.
The OEM connector is a standard 6.3 spade connector, with clip hold. I would solder and crimp the connections. Then grease the backs https://www.ebay.co.uk/itm/162635579362
" They all do that sir " ..... and I'm not joking . Sooner or later moisture gets it there , even in a dry climate there will be some moist air around ..... maybe coming from the expansion tank as it starts to fill with hot coolant ?? As @Chris and @Sev mention , once there is corrosion the connector becomes a little heating unit . Sadly not ..... what you have circled is a shaped grommet to keep the engine oil in . I reckon you have done an excellent job . Some folks want to keep their bike 100% original , and I get it , but for jobs like this , do you really want to throw stacks of money to keep it original ?
Not read the replies but you have to work out why it’s happened, usually it’s not just a simple case of the connector burning out, it’ll be either an issue with the stator windings or the reg/rec, you’ll have to check these and rule them out. Also check the battery and make sure that hasn’t been affected.
Hmm ..... Well it's because of corrosion on the terminals , usually due to water ingress , and nothing more than that . Alternator will be fine .... they are surprisingly rugged . Battery will not be directly affected ..... Happy Days ......
I was going to reply yesterday but its surprisingly difficult to write with a newborn on one arm! I don't think the Lithium battery was affected as the R/R (RMSTATOR, gorgeous but a tad on the large side: https://www.motoelectrical.co.uk/ty...00-650-955-1050-ducati-749-848-999-1998-2013/) is responsible for supplying DC to the battery and the burnout was on the AC (3 phase) side of things. As @oldtech said, it was down to corrosion and oil seeping up the stator wires that was the likely culprit. Just had the 999 back from the local Ducati wizard and he told me that Ducatis, Aprilias, etc are prone to this.
absolutely no harm in testing them just to be on the safe side, and just like I said the plugs don’t just burn out for no reason and if it’s due to corrosion and water ingress then that’s my point exactly.
