V6 yellow stator wires overheat go bad/burn easily

[pcrussell50]

So I have an old but good stator that I'm not using ATM. The two yellow wires have had a lot of the insulation overheated and cracked off...

I have heard here that people simply re-insulate them and get back with the show. I plan to do that in case i need to use this stator down the line at some point.

===

But what I want to know is what caused the yellow wires to overheat?

I feel like I read here in the past that the yellow wires can overheat either on basic 16A V6 motors that only have a rectifier and no regulator. I'm not sure I have that right though. Maybe the yellow wires overheat simply from having too much load from marine electrics drawing on them? That will not me my problem though. I use only a single small black and white, non-GPS, SONAR, mostly for water temp, speed, and voltage display.

Anyway, i'd like to set things up so my current stator (a nearly new CDI), doesn't burn out it's yellow wires. This 2.4/200 only has a rectifier, no regulator. But I'm happy to get a rectifier-regulator if that would fix things.

-Peter

[OnPad]

Too much load, or too little, plus crappy insulation, and bullet connectors.
Same problem with the 20amp reg/rec. The wire seems a bit better on the stators from the nineties vs. the eighties.

I have been procrastinating changing my connectors to gold, solder on bullet connectors.
521027

[ChrisCarsonMarine]

Poor connections create heat,Butt connectors with solder and heat shrink...problem solved,Chris

[pcrussell50]

That sounds like good pragmatic advice and all guys… But these yellow stator wires have simple ring terminals where they attach to the rectifier. Where would you even put quality solder connections?

-Peter

[OnPad]

Just soldering up the crimps will help in the long run on a ring connector, but I probably would swap over to a newer 20 amp reg/rec vs. a straight rectifier. On a recreation boat anyways.

I also have a old 9 amp stator with the yellow wires all jacked up. They must run warmer than the rest, and degrade the insulation. Which causes oxidation. I'm on the fence about trying to use it. Might have to cut my losses on the 40+ year old electronics. Or learn how to wind a stator.
521034