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I let my Corsaro idle for a while today to get some fresh fuel run through it (no MOT else I’d have taken it for a ride).

Afterwards I noticed the yellow wires on the left side of the frame from the alternator were very hot at the connector.

I knew this has been a weak point and some bikes have experienced overheated connectors here. Mine has been fine up until now, but it seems now is the time to do some sort of fix or upgrade.

Ideally I’d like to keep it as standard as possible and don’t really want to solder the wires. But ultimately avoiding overheated wiring is a must.

My bike is a 1st series with regulator under the seat and the factory ‘chocolate block’ fix at the regulator.

I am not averse to moving the regulator out into airflow as per the later bikes but don’t really want this to become an all encompassing project.

So, what have others done?

Hi Tom

I seem to recall that Roofus had the same issue. I'll ask him next time I see him, hopefully at the next Corsaro meet.

just clean the contacts very thoroughly, use some dialectic grease, and see if it is still happening.
replace the connectors with heavy duty ones, simple fix.
vehicle wiring products have some.

Just to update on this one-

I got some decent butt splice connectors and crimped these into the alternator wires, and run new wires all the way to the regulator, of a decent quality and larger gauge. Double insulated everything with adhesive heat shrink.

Now getting a consistent 14-14.2V on the dash and no sign of hot melty wires.