Wires coming from rectifier to stator getting hot

[Cameron456]

Well our 2012 ranger xp 4 900 burnt up 20 own regulators and we upgraded to a mosfet relocation kit and regulator and out on a camping trip the connecter between the stator and regulator melted, we hard wired the connection getting rid of any connector just straight wired to the stair to regulator, the wires still get really hot we went through all the convections and grounds, we are really stumped, any input would be greatly appreciated 

[InAquaVeritas]

I'd measure the output of the stator and whatever is using the power. It is either overcharging, has to deliver too much power, can't get rid of the power or has a massive resistance in the system somewhere. 

Are you running a lot of accessories? You might be maxing out the charging system, which is maxing out the wires. 

Check the wires for resistance, there might be a break in there, which would generate resistance and a lot of heat. Copper work-hardens and becomes brittle. I assume the caps in the second picture are the temporary fix, because that is a fire hazard waiting to happen in an ATV. 

There's also a chance the mosfet kit isn't working properly, allowing too much power through the system and maxing out the wires. 

Ideally, bring it to a Polaris dealer, who can read the ECU and VCM, to see what the system is doing. There might be a software issue, as the CANbus might be reading the regulator/rectifier and with the kit, might get the wrong signal. 

[Cameron456]

Thank you 

[InAquaVeritas]

You're welcome, I hope you figure it out!