How I fixed a common issue faced by multiple 2022 Aerox 155 owners

Yamaha service centres are recommending to change the entire wiring harness which costs about 13k

BHPian Speedracer47 recently shared this with other enthusiasts:

Hey guys, I want to highlight a common issue with the Aerox that almost 10+ people on the owners group including me have had. It is an issue with burning of the coupler that connects the magneto/alternator to the main wiring harness. This has been mostly experienced by owners with 2022 manufactured vehicles so not sure if it has been fixed later on or if it’s a matter of time before issues pop up.

The stock coupler seems to be inadequately selected by Yamaha for the wattage and is melting and ultimately giving up leaving the bike randomly stranded with a check engine light with a Crankshaft position sensor error ( Error 12). Yamaha service centres are recommending to change the entire wiring harness which costs about 13k and still with the same connector which might go bad again. So a seller on the group has come up with a solution of discarding the stock coupler and using MC4 connectors used for solar power in their place. These connectors seem to be of much higher quality that the stock connector and look like they should hold up better.

I recently had this issue on my scooter as well so I ended up switching out the connector with the MC4 connectors. You need a special MC4 crimping tool as well to crimp these connectors on. The scooter has been working fine again after the change. I will update here again if I face any issues. I recommend you guys with 2022 model scooters to get the connector inspected to avoid getting stranded on the side of the road in the most unexpected moment like I did . The connector is located on the right side of the scooter behind the footboard area in front of the radiator. Attaching pics for reference.

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