www.zxrworld.co.uk

Well my zxr400 is now off the road for abit of a clean up so whilst checking the wiring I noticed the wiring going to the voltage regulator had burnt through again,

What could be causing this as I've already had to fix this once

that doesnt look likea happy wiring loom...did you find out what caused it to burn out the wiring last time, or did you just replace the wire?

you reg/rec might have gone internally? if its failed and is sending high voltage through the wires that will melt them in no time.

Just replaced the wires last time and might have to buy a new regulator as the one on the bike is 2nd hand. It burns out very close to the regulator so could be that

What amp wire are you using, the alternator wires aren't that thick but if your using skinny wires for some of them the resistance will be too high and cause it to melt

ross46 wrote:What amp wire are you using, the alternator wires aren't that thick but if your using skinny wires for some of them the resistance will be too high and cause it to melt

The wire that have melted are from the original loom

Fair enough, just that you said you replaced it and in the pictures the wires are black with crimp connectors
#edit- was looking at the first picture, I see where its burnt through now, looks like there is some form of oxidation on it?

Yeah there is but the bike hasn't been out in the rain

doesnt neccesarily have to be water which oxidises it