Help with voltage regulator plug

[A@ron]

So I have been slowly working on my 2016 800 and found the voltage regulator plug to be melted. I’m curious if anyone has found a replacement plug that I can re-pin. I haven’t had much luck finding one. Buying a new harness isn’t in the cards for this sled. I will be putting a new regulator on it. Appreciate any input!

 

[BeartoothBaron]

I've had a similar issue with the stater harness on my Pro 800, as have many others; I think the same circuit and issue, although the wiring is different. What I did was to pull the two sides out, clean them up, and then move them to an empty socket (that part wouldn't be an option here since the AXYS uses all six sockets) - but mine wasn't as bad. You could just snip the wires associated with the damaged sockets and crimp a shielded male and female terminal on the respective ends and route them around the plug - making sure they're sealed somehow or another. Probably the best solution would be to replace the connector with something like this: https://www.summitracing.com/parts/prf-70406. An el-cheapo wiring tool could probably do the crimping, or you could buy one specific to it for $20. Another option would be to splice a new connector in; something like this: https://www.summitracing.com/parts/rnb-91445. Ideally, you'd solder and shrink-tube the wires; I wouldn't try an un-sealed crimp connector here.

 

[arcticridr]

Just go to NAPA and get a 6 pin weatherpak empty shell ( male/female):new weatherpak pins and seals and a crimper for said pins and some DIE ELECTRIC GEL and redo the whole connector . Prolly do this for $75.00 most expensive thing will be the weather pak crimper and the gel. Should us the gel in all the connectors , makes better contact and reduces internal heat!

 

[conk]

You should look into replacing the capacitors as well if your replacing the regulator I had my regulator fri then take those out as well took me a full season to figure it out had all sorta weird electrical problems till I did, like the low battery light flashing on the dash inconsistencies with hand warmers and made the exhaust have a different tone to it while riding but that was on a 2013 pro 800

 

[BeartoothBaron]

I just replaced the capacitor on mine; hopefully that fixes the intermittent low fuel pressure issues (I've already replaced about everything it could be, so hopefully it cries uncle). I very much agree with replacing the plug with Weatherpack (or a Deutsch; I hear they're as good or better, but less common) being the best solution; seal up the connector, and you'll probably never have the problem again. It's not as beginner-friendly, but not hard to figure out if you have the right tools. A couple years ago I broke down and bought a nice crimping tool set, and that's definitely worth having if you do much wiring work. Before you start, use some masking tape and number the respective wires on each side so you don't get them mixed up.

 

[A@ron]

Appreciate all the input!