Melted Stator Plug after new stator and R/R?

Question

Replaced the stator and R/R five weeks ago in my Honda PC80. Sarted having problems with the bike surging at lower speeds. As soon as I speed up it seems to be fine. So, I take the firing off and find that the stator plug is melted. So, could the new R/R be bad? Or can I just ditch the plugs and solder it?

Answer 1

Actually ,,,twist & soldering the connections would be a very good fix.

There's always a good potential for problems with crimp-on  spade connectors

Answer 2

Loose or corroded connectors will cause this too. They act like a resistor and generate heat which melts the connector housing. Make sure the connectors are clean and use a little electrical grease to help seal them.  

Answer 3

1980s Suzuki GS models had that same problem.

The fix was to remove the plastic connector block (between the stator & wire harness) and install individual connectors on each wire.

Make sure the connectors are insulated.

Use the highest gauge and amperage rated connectors as you can find.

Answer 4

It would be a good idea to test the charging system to make sure that the stator or R/R are not putting out too much power.