I'm reviving an old Yamaha XV535 Virago. It's running and passed roadworthy inspection yesterday, but it has one remaining issue before I take it for a real ride - its not charging enough. Battery voltage increases from ~12.5V to ~12.9V when I start it. Should be ~14V.

A lot of the electrical connections were very crusty - I've cleaned them as best I can with contact cleaner and mechanical scraping. The 4 pin connector from the pickup coils to the loom was particularly nasty and has been hot and I could not clean it enough so replaced it with a (knock-off) Deutsch DT connector and that's working well. The connector from the stator to the loom has also been hot. I've replaced the plastic shells and cleaned the connectors as best I can but I feel this connector may still be the source of my low charging voltage and I plan to replace it.

My options are 3 x generic bullet connectors or a single 3 (solid) pin Deutsch DT.

I know the DT connectors are not intended for "power" applications, but I can't find anything to say if the current on each of these wires from the stator would exceed the ~7.5A they are supposed to be rated for.

Thoughts?

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[–] 1 point 8 hours ago

Shoot an email to joe@cycleterminal.com

Small business that specifically sells motorcycle connectors. Let us know how it goes!

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