Voltage regulator wiring
 

Touch wood I've found my 600e to be reliable, it let me down once with a broken wire to the voltage regulator plug, resulting in a flat battery and a short push home. Voltage regulator is in a vulnerable place for moisture and an arse to get to with rack fitted. What's the best solution to stop a repeat of this breakdown, spray grease? Any thoughts would be appreciated thanks.

You want to avoid another broken wire?

Then clues can be had from the broken wire...

Is it a sharp clean break? Looks like it has been cut? Then it may have been cut at the factory and simply made contact by placement. Or it may have been cut by luggage. Examine the new wires for similar damage, and then protect them from luggage/frame etc.

Does the break show signs of ware - rubbing friction that wares through over an area? So protect the new wires from contact with moving surfaces. Possibly the wire itself moves with vibration ... tie it down so it does not move.

Correct, any wire that moves all the time WILL break. Use Black Plastic ties to secure any loose wiring. Good quality black ties resist the sun and should not get brittle and break.

More to do with wire corrosion at terminal, thinking about moving regulator somewhere more accessible, in the meantime will grease terminals and tape them round with self amalgamating tape.

Ok. Is there a more sheltered location? One with less moisture/water? :rain:
The connection terminals to/from the reg will also suffer from this too...

The grease is good. Add the shelter from water/moisture and it should be good.

Here .. city vehicles (coastal) suffer from corrosion and ware in low gears. Outback vehicle suffer worn suspension, ware in high gears. Pick two from the different areas and make one good vehicle (avoid flood damaged ones from the outback! doh).

that's the best place for the regulator rectifier! It needs the ground to dissipate the excess heat and there is a black wire (ground) that is secured on one of the bolts that also secures the regulator rectifier.

I added an old desktop pc fan, connected it to the rear presence/brake light and secured it with zip ties over the regulator rectifier to help dissipate the heat...

After you fixed the broken cable, have you fully charged the battery and has it kept full charge after driving for a while?