Wire melting

[aGUNS]

Ive been stumbling over this issue and im not sure what the problem is.

When I plug in my battery to my 81 gs550, the wire that leads to the cdi box gets way too hot and begins to melt.

any ideas?


thanks

[Guest]

Sounds like you are going to ground in the ignition module? I think it must be fried? Do a search to see if there is a test for the ignition module. I don't know if there is. Good Luck, Ray

[Steve]

First of all, you don't have a "CDI box", you have what is called an "ignitor", but we know what you mean.

On the other side of the ignitor will be a plug that goes to the coils and/or the signal pickups. Disconnect all of them and try connecting just the power wire (and the ground, of course). If the wire still smokes, you need a new ignitor. There is nothing "magical" about the box, it's just some transistors that replace mechanical points and interrupt power going through the coils. It is possible that one or more of the transistors has failed.

.

[Matchless]

Theoretically you should be blowing a fuse on your bike when this happens! Do you have the proper rated fuses fitted? What color wire is burning?

[850 Combat]

This is with the key off? What about the kill switch? It sounds like something may be connected incorrectly or shorted. I don't think the ignition should be powered up with the ignition and/or kill switch off.