Why Has My Stator Connector Melted :-(

The connector wouldn't melt because its faulty. I reckon if you replace it, it will happen again. You probably need a new regulator/rectifier, or its possible your stator is the cause. I can't offer much help but those 2 things are the prime suspects.

 

I agree with Andy, it will be the regulator/rectifier, it is a well known fault, I have replaced a fair few over the years on these models (amongst others), often the unit is poorly located and and gets little in the way of cooling, especially those on the GSXRs, I would recommend a quality replacement and avoid the cheaper Chinese made ones, if you look on the website of Bikerstoolbox.co.uk they have connectors suitable for replacing your damaged ones, I have put on a link to Electrexworld that can supply what you require.
http://www.electrexworld.co.uk/

 

I agree with whatever @andyc1 and @Iceman said.

They both sounded knowledgeable and coherent.

Far more than I am at the moment.

My guess, and I’m no expert, is that your electrics are fritz’d…

 

I had the same on my 1050ST. I cut out the connector and hard wired it and it was fine.
I have a charge indicator which is what alerted me to the issue and I would recommend fitting one.

 

Yes new stator needed to get over this one and perhaps the reg aswel if it has got damaged.
Joe

 

Not necessarily. This was my connector, the stator and reg/rec were fine.

 

Same thing happened on my FZR1000. I reckon it was corrosion on the contacts causing excessive heat build up. They seem prone to corrode and I have heard it is wise to coat them in Vaseline. I changed the connector and all was fine (and checked the charging voltage was not over around 14v).

 

There is a really helpful discussion about this on Triumph Rat, with suggested upgrades to avoid expensive repeat problems.

The big issue with the standard SCR shunt type regulators fitted to our bikes is heat, you probably get a very warm spot on the left under your bum after a fairly short ride. That is because the reg/rec can’t dissipate heat as it needs to, eventually leading to a failure.

The recommended course of action is to now fit a Series type reg/rec such as the Shindegen SH775 or 847. These are much kinder to Stators. You do need to get the plugs for them and there is a bit of fiddling about to fit them as the mounting holes are not the same distance apart, but I’ve done it on my TT600 and it’s a fantastic fix. It’s also worth replacing the connectors off both ends of the Stator wiring with the Delphi 280 waterproof plugs. These stop dirt oil and water getting in and protect that end too.

Link below

https://www.triumphrat.net/threads/...504/#lg=attachment_xfUid-3-1591131173&slide=0

 

For a high revving engine (your 600) the 847 is required. However as regards the mounting, on my Tiger I was able to mount the large reg/rec without drilling the frame. I used the lower hole and pivoting slightly on it I used a short strip of stainless steel and a countersunk screw for the upper mount.