Help! Mysterious Short from a Rectifier Wire - 77 KZ400

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07 Sep 2018 15:37 #790455 by Stockton350
I just got a 77 KZ400 for a fall project bike. The good news is that fired right up after replacing the spark plug boots and putting a little gas in it.

Bad news is that the wires to the battery began to melt this afternoon when I tried to start it up. I replaced those wires and checked the harness and everything seemed to be fine. But when I attached the battery, I immediately got a spark on the terminals. I traced the issue back to the white/red wire coming from the rectifier. For some reason, I'm getting continuity between that wire and ground. Can anyone shed light on this and what I should do?

When I leave that wire unplugged and only connect the battery to the white wire and grounds, the bike starts up fine -- no short at all. But clearly the white/red going into the rectifier is an issue. Help?

1975 CB125 | tinyurl.com/jds9l7q
1976 CB350
1978 KZ200 | tinyurl.com/j3odxo8
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  • perrykz1000
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15 Sep 2018 14:31 #790929 by perrykz1000
Mine did that once , check the solonoid wires one of the terminals on my solonoid was touching the wire going to starter. All fine till I tried starting then the wires got hot /smoking. Only when trying to start.

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20 Sep 2018 03:23 #791153 by Stockton350
Just an update to say that replacing the rectifier resolved the issue.

1975 CB125 | tinyurl.com/jds9l7q
1976 CB350
1978 KZ200 | tinyurl.com/j3odxo8
The following user(s) said Thank You: loudhvx

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