Dead Gixxer...

[kross]

In any case, do monitor it for a while.

QFT. I had a similar problem on my CBR and chased it for days. I bought a new battery, and two days later it was dead. I replaced melted connectors with more sturdy ones, that led to melted wires. When I replaced the sections of wire with heavier stuff, it would melt somewhere else.
Turned out all the things I was replacing were symptoms of a bad reg/rec, not actual causes of the problem. The reg/rec wasn't doing it's job, undercharging the battery. It seems the excess voltage from the stator had to go somewhere, so it showed up as heat in the weak points of the wire harness from the stator to the reg/rec.
I'm not saying you've got the same problem, and I'm sure mosquito did a very good job, but I've spent enough time on the side of the road checking wires and connections to confidently tell you it's way easier to spend 15 mins doing it in the comfort of your own garage. Now that you know what to look for, it probably won't take you too long to check it over now and then for the next week or so.

 

[mosquito]

Thanks, kross. That's exactly the sort of ultimate cause I'm concerned about, particularly if it's actually failing only after it gets hot, with something like, e.g., one of the rectifier diodes failing. It checks out fine in the garage when the electrical components are cold, but it could be a different story after 20
minutes on the freeway.

 

[Gixxergirl1000]

Thanks, kross. That's exactly the sort of ultimate cause I'm concerned about, particularly if it's actually failing only after it gets hot, with something like, e.g., one of the rectifier diodes failing. It checks out fine in the garage when the electrical components are cold, but it could be a different story after 20
minutes on the freeway.

So should I plan on replacing the reg/rec next month, then? I mean, it's easy enough that I can do it without help!

 

[Hooli]

So should I plan on replacing the reg/rec next month, then? I mean, it's easy enough that I can do it without help!

Ron Ayers sez:

32800-33E21 RECTIFIER ASSY $153.86

 

[mosquito]

Personally I don't like replacing parts unless they're known to be bad, 'cause it can be a total waste of money and a false sense of security if the problem is actually somewhere else. Want to test it hot?

 

[Gixxergirl1000]

Personally I don't like replacing parts unless they're known to be bad, 'cause it can be a total waste of money and a false sense of security if the problem is actually somewhere else. Want to test it hot?

That would be good! What do I need to do?