98 GSXR750. Error code showes bad cam position sensor. I replaced it and upon further inspection noticed that the wiring harness is melted. Replace wiring harness and bike started but ran like poop. Would not idle properly, thick black smoke (unburnt fuel) when throttle opened. Turned off bike and the new wiring harness started to melt right at the plug for the voltage regulator. Any ideas? I am at my wits end. BTW, the voltage regualtor was replaced with the wiring harness. All fuses are still good and the proper size. HELP!!!

Hook it up to a volt meter see how much power the genorator is putting out. images/icons/confused.gif

Thanks dirtybird. I will give that a try. Do you have any idea as to what voltage I should see?

Does anyone else have any suggestions?

There's a resistance problem somewhere. Mine melted 2 used harnesses the same way. I had to replace the front and rear harness, stator and reg/rectifier w/ brand new factory parts to get it to run$$$$$$$(Suzuki says "thanks" too).
I saw a shit load of corrosion in the connector that joins the front harness to the main. There was also a burned pin connector in it. Good luck, I hope you don't have to shell out too much $$ to get it going.

Hey Dirtybird, you need help riding all those bikes????

with the bike running you should have around 13.5 volts across the battery, with 12v with the bike off.

I would guess it is a stator problem. and as bill said it will take out your regulator. If the harness burnt at the regulatorthe reg/rectifier is probably toasted. I would recommend taking to a shop and be ready for some money to be spent

Well i would check the voltage coming from the magneto to see if it is to much..

Also the plug on these bikes are VERY well knowen on this site for melting with nothing else on the bike having a problem. I have seen it happen to MANY bikes. If everything checks out right then I would just hardwire the regulator like everyone else does.. images/icons/smile.gif

John

Originally posted by Bill:
Hey Dirtybird, you need help riding all those bikes????<font size="2" face="Verdana, Arial">A bit off-topic but graemlins/laugh.gif

Originally posted by Bill:
There's a resistance problem somewhere. Mine melted 2 used harnesses the same way. I had to replace the front and rear harness, stator and reg/rectifier w/ brand new factory parts to get it to run$$$$$$$(Suzuki says "thanks" too).
I saw a shit load of corrosion in the connector that joins the front harness to the main. There was also a burned pin connector in it. Good luck, I hope you don't have to shell out too much $$ to get it going.<font size="2" face="Verdana, Arial">Bill -- I think my bike has a Shorted Wiring Harness somewhere ... I have ran the Rectifier and Stator checks and those passed. now I am down to looking for a Shorted "something"

... do you have any tips on what I should look for?

hey im stating to think u guys should take ur bike to a shop and get them professinally fix stop being so sheap (bring them to my shop graemlins/thumbup.gif

Originally posted by ridder994:
hey im stating to think u guys should take ur bike to a shop and get them professinally fix stop being so sheap (bring them to my shop graemlins/thumbup.gif <font size="2" face="Verdana, Arial">I'll do that as soon as the local shops stop dicking around with me images/icons/grin.gif the last shop I took my bike to had their mechanic use my bike to run a bank errand, and then comfortably took my $400 steering damper and frame sliders ( graemlins/icon_wtf.gif ) to use on his own personal bike.... all coz he wanted to 'try it out.'

[ 01-07-2003, 11:59 PM: Message edited by: migz123 ]