Melted most of my wire harnass!!!

So,im about to take my 1st ride on my newly reconditioned 77KZ650.Now Ive run her plenty of times in the last few weeks with no problems.I just wasnt finished with everything so I couldnt ride her.So,I put gas in,turn the ignition on,choke it,and hit the starter button.She starts up after a few trys.20 seconds later smoke starts coming out of headlight!So I turned off the ignition switch,took the key out.Now I notice smoke/flames under my ass!Quickly pop seat,meanwhile my guage lights come back on(Key is not in and start run switch is off).Had to find tools and disconect battery in order to stop the bombfire!After inspection most of the damage seems to be coming from the rectifier.Black and yellow wire completely melted through out entire harness(now ready to literally through up!)Most of harness at the rectifier end is melted.
Anyone care to take a stab??
Anyone have a rectifier and wiring harness for said bike????Please help!!!

Post edited by: BoZ650, at: 2007/10/20 15:40

Man, i feel bad for you:( When you ran the bike the previous times did you do any electrical system checks? Like how much the alternator was putting out? What size are the fuse's?

Alt was putting out 13.5 volts check at batttery,and the 20amp main fuse should have blown.I wish it would have!!!!Thanks for asking.Any thoughts???

I may have a rectifier, harness, and stator for that bike. I'll check. Send me a PM with your phone number so I can call you.

That is really not so unusual several members here with 77 650's have had rectifiers go up in smoke this year. It seems like 30 years is the max for that part. I replaced mine with one from this guy oregonmotorcycleparts.com/rectifiers3p.html

I was real pleased with his service and he guarantees them for life. Only cost me $45.50 as well.

Gringo,yeh I found that guy on ebay!He seems real cool!Im probably gonna pick that one up even if just for a spare!
I also have a combination rectifier/regulator off a newer 650 but im not sure if i want to get involved with trying to wire it!Has anybody done this?You've all seen how I wire things,Idont want any more fires!!!
Ten6 i private messaged you but im interested in that set up you have too.

Post edited by: BoZ650, at: 2007/10/21 05:35

The only way to resolve a situation like that from scratch is to fasten the harness to a piece of plywood, trace 1 wire at a time to it's source and replace it with new.

Sound boring? It is.