New Strange Issue...

[N4HHE]

I would not solder the crimp connectors if installing a new plug. Solder in stranded wire is bad. Heat melting insulation is bad even if you don't think you damaged it.

For mil spec and NASA electronic designs we could not solder stranded wire. We could crimp a connector to the wire then solder that connector to a PCB but could not solder the wire direct.

[chazglenn3]

After fighting with it today I think I'm going to cut the old wiring and route the replacement a way that is convenient for me. They have it running a way that is borderline impossible to get the old one out.

[raYzerman]

Are you hanging up on the connector? Perhaps just release the terminals and remove the connector..... note inside the frame you have wire harness and clutch tubing and some other wiring. Give it a shot.... if only to have a path for the new one....
I realize your old one is toast, but you gotta fish the new one back in.........

[chazglenn3]

I was hanging up on the connector. Finally ended up just cutting it off of the toasted stator and pulling the wire through. I totally stripped out the wire clamp screw in the donor stator cover and as I was running out of time, I just installed the donor unit as it is. The stator cover is scratched all to hell but the stator works! I made my own routing for the harness over the shift linkage and through the hole in front of the rear shock. Fired her up and she is charging like a champ! At some point when I have more time to work on it I'll get the covers swapped and the R/R swapped as I didn't get to that either.

[FJRoss]

Great!
I assume that the ABS light is off.
Did you clear the fault codes and did any come back? I would watch for those - especially #14. Sometimes caused by a buildup of "goo" in the rubber hose (fiche part #12) that runs from the MAP sensor (fiche part #17). The rest of those hoses usually stay clean. If #14 comes back, the bike won't run properly but the fix is easy.
Edit to add fiche link:
https://www.partzilla.com/catalog/yamah ... b/intake-2

[chazglenn3]

The ABS light is indeed off. I did clear the fault codes but I haven't checked to see if any have returned yet. I'll have a look tomorrow.

[raYzerman]

Most should not return. From what I saw, they were mostly caused by low battery or a disconnect at some point.....

[FJRoss]

Most should not return. From what I saw, they were mostly caused by low battery or a disconnect at some point.....

Yup. The #14 is the only one I thought might have had an unrelated cause. Something to watch for in any case; especially for an early Gen II.

[Hppants]

I always enjoy a happy FJR ending!