my electrical problems continue

[Kawi 800]

so last summer at the end i had a small electrical problem, long story short i had some fried wirers. So i just put a new voltage regulator and got a 750 magneto. Now i re wired everything but when i crank it for more then a few seconds it starts to smoke. So i replaced the wire and its the black one that keeps getting hot and im lost at what to do?

Ha anyone go or going total loss ha i would like to replace my whole front electrical stator and wirers.

Let me know if you have any advice.

 

[starter kill]

pics?

 

[Antizerg]

something is wired wrong or something is shortening out, changing the wire is not your problem, something is going on to cause it to smoke. without a multimeter its hard to tell from over the computer. but to start off your troubleshooting will be simple, just look at both ends of the wire and go from there...possible jacked up stator

 

[SUPERTUNE]

Are you talking about your stator wires being fried and now the replaced stator wires are getting hot when you try to start it?
If your answer is yes, then you need to replace the main ground cable from the battery to the starter.
A bad ground cable and is trying to use the stator wires as a ground for the starter.
Starters use way too many amps and fries stator wires FAST!

 

[Kawi 800]

SO my negative battery cable could be bad? i will replace it and see what happens.

 

[Kawi 800]

Replaced the ground cable to the battery, that black cable off the stator is still getting way hot and smoking....

Anyone have a picture of the insoid of the electrcal box could the ground wirers in there be on wrong?

 

[Kawi 800]

OK so i cut the black wire from the stator and grounded that. It dosent get hot, the wire thats inside the electrical box coming off the voltage regulator that plugs into the 3 prong conector that goes to the flywheel mcover is. I tried to ground that wire off the voltage regulator and its getting a massive amount of power. I have eliminated the front of the motor electronics and feel it is somewhere in the e box now, could i have picked up a bad voltage regulator? Its brand new......Could it be wired wrong?.........or could a wire have a burr on it of some exposed wire and it be touching the voltage regulator?.............One more thought everything in the e box that gets grounded i have grounded on the voltage regultor except the voltage regulator could that be my problem?

 

[Kawi 800]

ttt

 

[Kawi 800]

I got a new electrical box to try. Its from KX454's ski. When i put it in and had the groumnd wire cut from the stator to the e box it would not crank, when it was grounded it would crank no problems.

now when i do the same thing to my e-box with the black ground cable from the stator to the e box cut, it will crank even though its not grounded. Could i have a short someplace im not looking?

 

[tom21]

yes. if I understand you correctly the only ground to the ebox is the stator wire. so if there is a short on any of the ebox wires it will heat up that ground. you will need a voltmeter to test this. got one handy? or you could unplug everything in the ebox and start reconnecting to find which one heats it up.