Bonneville America Forums Forums Technical Forums General Tech melted wire connectors

once a year I have to cut off and replace the same wire connectors under the seat of my 02 America because they are melted. This is the connection point from the igniter to the blue-black wires. Last year I used shrink wrap and tape to keep them sealed but they still burned through. The gap at the ignitor is .08 as it should be. I haven't burned any fuses and have no extra attatchments that draw current. This is my second ignitor but the problem existed with the first one also. Any ideas as to what may be causing this? The bike runs fine otherwise.

Are they plug together type connectors?
If so, try using either ordinary electricians connectors that you use a screwdriver on (chocolate blocks we call them over here), or better yet through crimps, though these are single use only and you have to cut them off to disconnect for whatever reason, you have to get the correct size crimp for the cable and they are better being crimped with the proper tool but you can use pliers. Properly done, crimps are pretty much vibration proof. Of course, I don't actually know if you can get them over there

As long as its dry under your seat and everything is electrically insulated, I wouldn't seal them up so that the heat can dissipate

Hope this helps

Connectors will melt when there's too much current (as you've already figured out), but one thing people often miss is that there's more than one way to create an extra draw. If the connectors aren't firmly connected, or have some sort of film etc between them it turns the connector into a resistor which will create an extra load. Make sure the connectors are clean & shiny when you put them on, and protect them with a little dilectric grease (or even vaseline at a stretch) to stop water/condensation/humidity getting in and corroding them.