Had a failure the other day. The wires from the alternator melted as is the norm on these bikes I have cut the wires from the alternator back and I am pretty close to the case. The wires look OK until the sheath is stripped off and the copper looks to he covered in verdi gris. After cleaning up the wire with emery I used a heavy guage chocolate block connector to connect the wires and ran the bike. The alternator wires got hot but the heavier wires I had fitted to the reg/rec were cool. The reg is fitted behind the number plate on a big ally plate My intention is to fit bigger gauge wire directly from the stator Before I pull the case and remove the stator has anybody done this.
Someone on Ducati.ms did it but it’s been a couple of years since I read it and I struggle to remember what I had for breakfast this morning. Might be worth having a search on there.
Yes, I did it to my son's Strada about 10 years ago, it wasn't difficult. I had to remove the alternator and the screws securing the stator. To get the stator out I lightly whacked the cover face down against the bench. I unsoldered the wires from the stator and replaced them with heavier wires. I can't remember the gauge but it was at least 3mm sq. I couldn't buy that size wire as a twin core insulated pair so I used individual wires inside heat shrink for their entire length threading it through the compression gland and replacing the OEM connectors with Powerpole connectors using 45A terminals. It has given no problems since.
Yes, it's pretty straight forward. I used a cable used to connect cookers to the 45 amp wall outlet. Happens to have that at home and it fits perfectly in the hole so was easy to seal up. Much thicker than the original wires and no issue since.
I carried out this mod' quite a few years ago now on my 851, the same alternator as the 916's. Here's what I did... Replaced the wires with heavier gauge silver coated/plated wires (2 single wires covered with heat shrink), for the connectors I used gold plated bullets (no chance of any corrosion) that I got from a radio controlled model shop soldered to the wires, then covered them with heat shrink. Mounted a Mosfet reg/rec to a alloy tail tidy/heat sink behind the number plate, then ran the same heavy gauge wires to the battery, with a 30amp fuse in line to the positive side of the battery. I used the Mosfet because I was also using a Lithium lightweight battery. This set up has been ABSOLUTELY bullet proof in use for 10's of thousands of miles since. Steve R
When I did mine I used silicon cable with multi core, its used for lipo batteries in the modeling world and very flexible, available from most model shops,mines been trouble free for 8 years now. Steve I think I used 12 AWG but possibly 10AWG.
