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JR, if I am reading his posts correctly, he has voltage on both sides of the diode. This may be perfectly normal, depending on the circumstances. Here's why.

If the bike is running, you have rectifier output on the anode lead of the diode. Whether the bike is running or not, you should have battery voltage on the cathode side (unless the 20A fuse is blown). If carefulrider is checking for voltage with the bike running, voltage will APPEAR on both sides. In normal operation, the diode will switch on when the anode lead voltage is higher than the cathode. This allows the R/R to charge the battery, but prevents drain on the battery if the R/R fails to output enough voltage.

This seems similar to insanetexan's issue. My thought is that the voltage regulator is either not shunting excess voltage to ground correctly, or the ground lead that it uses to shunt the voltage is open or high resistance. When this shunt circuit doesn't work correctly, the excess voltage will seek out the best ground it can, and that seems to be through the lighting circuit, as that is the connector everyone reports melting. If the ground lead from the R/R measures short to the chassis, I would replace the R/R.

A question I have, based on this wiring diagram, is why they designed a 3A fuse for the horn circuit, but no fuse for the lights? I wonder what current that light circuit is reading when the connector gets hot. I would bet it's over 15 amps. I don't think the lighting switch was designed for that. 25-35 Watts for each headlight plus about 20 Watts worth of running lights only equals between 4-5 Amps on a normal basis.

JR has a point. I cannot think of any circumstance in which it is good to have fuel IN your vacuum line. That teaspoon of fuel would dampen any vacuum input to the pump.

I got the swingarm in today from powersportsbest.com. The design of the area that cracked is better. The frame is thicker and better reinforced. I like that it came with a bearing and oil seal already pressed in, what would have cost 15-20 bucks more had I ordered them. The bearing from ebay will go into my parts bin. The major problem I have with it is there used to be a third tower (muffler mount?) that they obviously cut off and ground down with an angle grinder. It looks sloppy and they took the paint off. So now I have to repaint it myself before install. I would have recommended this supplier had they not done that.

I had a weird experience with jclusa. I placed my order, where it sat in a 'pending' status for two days. They never asked for payment info. So, I called the number from the site, and a computer began asking questions about my age and such, like it was a survey or something. I double checked I had the right number.

So, I ordered a swingarm from powersportsbest.com, which I believe is a sister site of roketa.com. $121 including shipping.

The bearing is really stuck in the old one, and I figured I would destroy it by trying to get it out. So I ordered one from ebay for 3 bucks. From what I have read, it takes a 6303-2rs. the 2rs means it is a sealed bearing.

While I got her apart, I'm also replacing the belt with a new Gates, and upgrading to sliders.

Thanks, JR. I talked to Jeff at FX. They don't have one, except for one that the seller only wants to sell the whole bike. He recommended calling Scrappy. Already have tried Scrappy, no luck there.

I will order it tomorrow morning from one of the two sites I mentioned earlier. For added security, I will be replacing the bearing as well.

A couple miles from home, I noticed the rear just did not feel right. Made it home and noticed that my swingarm had broken at BOTH motor mounts. The only things keeping it together were the wheel nut and shock absorber.

So, I need a replacement. Found out it's not the easiest part in the world to find. I did find 3 sites that list it. Roketapartsdept wants $231. Too much. But Roketa.com and jclusa.com have them listed for much cheaper. Given the English is poor on both sites, I am concerned about questions or returns.

Does anyone have experience with either roketa.com or jclusa.com?

Thanks.

That looks like the swing arm mount. It cushions the motor from the frame, but it's not in a place I am used to seeing it. On my JCL, it's connected to the large U-shaped frame crossmember under the seat. I'd have to see more pics from different angles (and behind) to see where it goes. It does look to me like it hasn't been missing for long. Otherwise, the cup would have the same road dust as the other frame pieces.