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2016 690 Duke
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That is the connector for the stator to the regulator/rectifier. The yellow wire side should go through the left side engine case and the grey side should got to the R/R.

It looks like its seen some heat and is melting. This can happen when the connections are loose or dirty which will build resistance and generate heat.

Are you having electrical issues with your bike? Specifically charging system issues? I suspect that if you are not now, you will be soon.

I would take voltage and resistance readings for the electrical system to see if there is an issue. And I would, at a minimum, clean/inspect and grease the heck out of that connector if not replace it.
 

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Ah yes - I remember this issue on my 990. Oil can weep into that plug. Like Pavement sez, I would change it if you know how to (pull the pins out and swap to a replacement plug). Its been so long but I remember swapping to a sealed plug...not sure what part number. This was 2009 for my 2008. It was a Molex style but sealed.

You do not have to go that route. You could literally pull the pins, clean them and that plug, re-insert and seal the pins in place with silicon sealant on the backside.
 

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Discussion Starter · #4 ·
That is the connector for the stator to the regulator/rectifier. The yellow wire side should go through the left side engine case and the grey side should got to the R/R.

It looks like its seen some heat and is melting. This can happen when the connections are loose or dirty which will build resistance and generate heat.

Are you having electrical issues with your bike? Specifically charging system issues? I suspect that if you are not now, you will be soon.

I would take voltage and resistance readings for the electrical system to see if there is an issue. And I would, at a minimum, clean/inspect and grease the heck out of that connector if not replace it.
no electrical issues, i put contact spray in all plugs every time when i do chain and other lubrication, can be this be caused by bad r/r? sorry if you dont understand something its not my main language :)
 

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Discussion Starter · #5 ·
Ah yes - I remember this issue on my 990. Oil can weep into that plug. Like Pavement sez, I would change it if you know how to (pull the pins out and swap to a replacement plug). Its been so long but I remember swapping to a sealed plug...not sure what part number. This was 2009 for my 2008. It was a Molex style but sealed.

You do not have to go that route. You could literally pull the pins, clean them and that plug, re-insert and seal the pins in place with silicon sealant on the backside.
can you put link or some picture of connector, it seem to need big plug, i can find only small sealed plugs. i dont want to put small plug on wire that big, it will build heat
 

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2016 690 Duke
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no electrical issues, i put contact spray in all plugs every time when i do chain and other lubrication, can be this be caused by bad r/r? sorry if you dont understand something its not my main language :)
When the plastic of the connector is getting hot enough to start melting, there is a problem somewhere. Most likely in the connector. As the plastic gets soft it allows the connectors for the individual wires to shift around essentially creating a bad connection. This will eventually cause a failure in the charging system.

If you don't have an issue with your charging system, you will soon.
 
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can you put link or some picture of connector, it seem to need big plug, i can find only small sealed plugs. i dont want to put small plug on wire that big, it will build heat
I do not have any other pictures of my 990 setup anymore. Sorry. This was 15 years ago.

When the plastic of the connector is getting hot enough to start melting, there is a problem somewhere. Most likely in the connector. As the plastic gets soft it allows the connectors for the individual wires to shift around essentially creating a bad connection. This will eventually cause a failure in the charging system.

If you don't have an issue with your charging system, you will soon.
Agreed. Something is getting that wire or area hot enough to melt the plastic. You may want to pop off the stator cover and have a look at the windings
 
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