Author Topic: '78 CB 750 reg/rec plug melting, why?  (Read 884 times)

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Offline timdhawk

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'78 CB 750 reg/rec plug melting, why?
« on: December 23, 2020, 04:17:54 PM »
Hey gents,

What could be causing the plug on 1978  cb750 reg/rec to be melting? I'm running a Shorai Battery and use their dedicated charger/refresher.

(On a side note, I've thought I've had a slow parasitic electrical draw for a while... could this be related?)
In deeper than I should be...

Offline tlbranth

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #1 on: December 23, 2020, 08:27:20 PM »
That connector is inadequate for the current flowing through it. After a while oxidation will cause a worse connection and subsequent overheating and melted plastic. The real fix is to chuck the connector and replace it with something more substantial. I used Anderson powerpole connectors. Easy to use and capable of handling the ciurrent.
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Offline scottly

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #2 on: December 23, 2020, 08:40:37 PM »
There shouldn't be that much current through the rectifier, unless the rectifier was faulty. Is this a cheap ebay reg/rect? Also, you should be using a lithium compatible regulator with the Shorai battery.
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Offline Bodi

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #3 on: December 23, 2020, 09:36:39 PM »
The basic answer is Ohm's Law. This is the red wire from my inspection of your images. That carries the rectifier DC output to the battery and the bike's load. A faulty connector starts to gain resistance: Ohm tells us that P=I²*R - power is current squared times resistance. A connection with zero Ohms makes zero power: this is not possible, of course, as any wire or connection has a resistance.
The spade connection, in perfect condition, has a very low resistance. As it ages that resistance rises, and current through it produces more heat. The heat accelerates corrosion, increasing the resistance, increasing the heat produced. At some temperature the metal of the female connector loses its springiness, contact pressure goes down, resistance goes up, heat increases.
A 1/4" spade connector can safely handle 20 Amps or more when in good condition.
The CB750 alternator, at full output and at riding RPM, makes around 220W or close to 20 Amps.

Apparently your connections are not in good condition.

It is not possible to get more than about 20A out of the alternator. Using a 750A field coil will get a bit more but do you have one?

So the basic fix is to fix the connector. The spade terminals can be removed from the shell and replaced. Careful cleaning of both ends, and adding a bit of tension to the female end helps it make a good connection, but if that has overheated then it has to be replaced. Possibly the wire connection to one of the terminals is the problem.
Or you can solder the wires together with good insulation (this wire is an unfused connection to battery +).

Possibly - unlikely - a rectifier diode has failed short and a very high current is flowing from the battery back to the rectifier. That would cause rapid battery discharging and other serious electrical problems.


Offline scottly

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #4 on: December 23, 2020, 09:41:41 PM »


Apparently your connections are not in good condition.
The connectors appear clean and bright, with no corrosion..
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Offline bryanj

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #5 on: December 23, 2020, 11:28:37 PM »
Its 42 yrs old and tired OR its a cheap repop
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Offline PeWe

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #6 on: December 24, 2020, 01:09:32 AM »
IF that wire is ground related....

When your starter motor has bad ground from battery via correct thick wire that should have good contact with engine and frame.
The ground over rectifier will take the hit when starting the bike.
Same with old stock rectifiers as I have seen for CB750 and similar.
I added an extra grounding wire on my rectifier to battery just for sure, 4mm2 wire to ensure not melting rectifier ground wire and its connector.
Hondaman recommendation.
« Last Edit: December 24, 2020, 01:29:43 AM by PeWe »
CB750 K6-76  970cc (Earlier 1005cc JMR Billet block on the shelf waiting for a comeback)
CB750 K2-75 Parts assembled to a stock K2

Updates of the CB750 K6 -1976
http://forums.sohc4.net/index.php/topic,180468.msg2092136.html#msg2092136
The billet block build thread
http://forums.sohc4.net/index.php/topic,49438.msg1863571.html#msg1863571
CB750 K2 -1975  build thread
http://forums.sohc4.net/index.php/topic,168243.msg1948381.html#msg1948381
K2 engine build thread. For a complete CB750 -75
http://forums.sohc4.net/index.php/topic,180088.msg2088008.html#msg2088008
Carb jetting, a long story Mikuni TMR32
http://forums.sohc4.net/index.php/topic,179479.msg2104967.html#msg2104967

Offline drumstyx

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #7 on: December 24, 2020, 04:19:45 AM »
Well, that's not an OEM reg/rec, since the original regulator and rectifier were separate components. I replaced mine with a Rick's Motorsport Electrics reg/rect unit, and have had no problems with an aftermarket replacement harness (read: new connector).

These connectors are very easy to disassemble -- you can replace the plastic with something quality, and to reduce heat you can replace the individual terminals with beefier metal.

As others have stated, check grounds and various other connections (check wiring diagram). The connector shouldn't really heat up at all, so any heat-related fixes are just bandaids anyway.

Offline timdhawk

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Re: '78 CB 750 reg/rec plug melting, why?
« Reply #8 on: December 24, 2020, 09:08:55 AM »
Thank you all so far. It's not an Ebay cheapo special reg/rec. I'm pretty sure I bought it from Ricks years ago. At the time I bought it I wasn't aware of a difference for Lithium batteries. I'll start with replacing the reg/rec for a Lithium one and maybe upgrading the connector. Thanx for the help so far!

Merry Christmas / Happy Holidays!
« Last Edit: December 24, 2020, 09:11:18 AM by timdhawk »
In deeper than I should be...