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Melted power wire?

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Guest

Guest
I just upgraded my 78 GS750 to a SH775 R/R a week or so ago and today I broke down. I don't think these really don't have anything to do with each other but figured I should mention it. I've put about 80ish miles on the bike since the R/R install with no issues. After riding about 4 or 5 miles today, I was accelerating at a rather brisk pace and lost all electrical power and the bike shut off. I figured I had blown the fuse on the main power wire and I was correct. I did not have a screwdriver with me to pull the side cover off so the best I could do was pull off the fuse holder and connect the harness side of the power wire to the battery. I had thought the fuse was very old (I have never replaced it) and that it just popped from being old. Anyway, I loosened the + terminal and clamped the end of the power wire into it to limp it the few miles back to my house to make a repair. At his point I hadn't turned the key on and was putting my gear back on. The wire had been connected for a minute or two and all of a sudden the wire just completely melted itself. I'm not sure how far up the harness it went but I would like to cut the harness apart and replace the whole length of wire just to be safe. I'm fairly well versed in electrical stuff but I guess my question is what would cause this with the key being off? After I got it home I hooked the wire back up just to see (with a fuse this time) and it popped it immediatly, again with the key off.

I have upgraded to the SH775 R/R and I have LED turn signals and a Wideband O2 gauge on the bike, everything else is stock. I should mention that I wired the R/R with its own 15amp fuse to the starter solenoid to clean up the wiring under the seat and the O2 is wired with a relay to the solenoid as well. I have also made a ground wire from the battery to one of the bolts for the starter relay and all the other loose grounds are connected at that common point.
 
Sounds like you have a dead short somewhere; one of the always hot power wires is shorted to ground. I'd trace all your mods and look at those circuits first.
 
Found the problem, the wires from the old rectifier must have fallen below the battery box and I didn't see them to tape them up during the install. At least I think that's the problem. I'm really kicking myself now :mad: do you think there's any damage to the stator or r/r. I think I'll get away with just replacing the short section of wire that burned
 
Simple charging system test is the run the bike at 5000 rpm and check voltage at the battery - should be about 14.5 VDC.
 
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