What would cause Stator connectors to over heat and burn?

[Modmike]

I thought one of my stators was fried. As I prepared to test it, I discovered that the connector was internally carbonized from over heating even though it looked perfect on the outside.

I replaced the connector using a Deutsh connector kit I bought on Amazon and now the stator works perfectly.

I inspected the other engine and saw the wires were overheated on the outside but the inside was perfect. I replaced it anyway in case it was arcing internally.

What could cause the connectors to overheat like that? Is it a known and common issue?

 

[WaTeRMaNiaC407]

I found that this is a pretty common issue. It happened to me twice. After the second time I changed out the Deutsh connectors for some barrel connectors and never had the issue again. I think that the pins in the Deutsh connector are just not large enough to carry the current. This seems especially true if you have an amp running, dual batteries or extra equipment that requires more current to keep the battery charged.

 

[Modmike]

I have dual batteries. A little mad with myself for insisting on replacing with same connectors. especially when I had a nice weather pack connector kit lying around.

Thanks for the help!

 

[Joe Starbuck]

You are not the only one who has seen this. My first reaction is corrosion on the pins creating a resistance that in turn creates heat. However, the Deutsh connectors are specifically designed to keep environmental contaminants out of the pins. The pins themselves are nickel plated copper. Are you in salt water? 90/10 copper-nickel (or Cooper Nickel) is proven to stand up to salt water, but I have no experience with nickel plated copper.

 

[Modmike]

35 hours on engines, pulled out after every use, and in fresh water only.

 

[pretex]

Had the same problem on my Challenger 230. Changed all the connector pins, crimped then soldered them to ensure a solid connection. I did this after diagnosing an overcharging issue, I also change my regulators out. They were charging over 16volts causing the CEL to come on.

 

[Modmike]

I checked my rectifiers and stators after I replaced the connectors and they were all good. Next time I will go with Weather Pack connectors, those deaths pins are just too small.