The regulator/rectifier connector is undersized for the FZ1. It is marginal in its ability to supply the current level that is being demanded when:
Several members have only determined this after the connector has melted and the rider gets stranded.
The three white wires in this connector are all above ground and supply the three AC legs of the alternator as an input to the regulator/rectifier. For comparison find the three white wire large connector under the left side cover. This is in series with the burned connector, carries the same amount of current, and has terminals twice the size.
The red and black wires are the current output of the regulator/rectifier and feed the battery and the rest of the electrical system. Note that the charging system is rated for 18 amps of current, and that the type of terminal being used in this connector is generally used in applications of 8-10 amps maximum. So, when you get in a situation where the charging system has to supply current near full capacity for an extended time, the terminals heat up and self destruct, melting the connector shell. This is a common failure on the FZ1 and also the earlier R1 models that shared this design.
This connection system will work well and is adequate to handle heated accessories. This is a low-resistance connector, made of silver-plated copper. The secret of its success is the stainless steel leaf spring built into the plastic housing. This spring applies 25 lb of pressure onto the contacts, ensuring good, vibration-proof contact. Contact resistance has been measured at 600 micro-ohms.
Make sure that the red is in red and the black is in black. The order of the three white wires does not matter. They can mate with any of the three white wires to the regulator.
The information presented here reflects solely my personal experience with my motorcycle and is presented for entertainment purposes only. No information presented here is to be relied upon for issues of rider safety or to replace the services of a qualified service technician. Any attempts to follow or duplicate any of these procedures are done so completely at your own risk. By reading the information on this site, you agree to assume complete responsibility for any and all actual or consequential damages that may arise from any information presented herein.