Heres what happened:

After market R/R, stock stator, runs fine for 3 months and then i start it and in five seconds i see white smoke and the plug going from the stator to the rr is compltely fried, and the plug from the rr to the main harness is also toast. I assumed it was a bad rr.

Replace the rr with a oem honda rr, the wiring harness with dogstars harness(Thanks man!) and the stator with an aftermarket stator, here is a link to it

http://cgi.ebay.com/ebaymotors/ws/eB...:IT&ih=005

put it together and everything is fine, ride about 50 miles everything is fine, then i get on the highway and take about an 80 mile ride and everything seems ok, stop at a buddies house and then start up and leave there and ride another 20 minutes, i stop at a gas station and then go to start it again and its dead. This i imagine is about the time that all of the stator wires were burnt almost completely through. So i bump it and take off riding somewhere where i can store it for the weekend since it was acting up. Go back there to ride it home(had to bump start it) and on the way home after,about ten minutes, it dies on the highway, so i pull over, swear at it for a while, and leave it there. I finally get it home in the back of a pickup truck and take it apart and the three yellow wires from the stator are burnt completely through, not even connected to the plug end anymore. The plug is ok, the rr is ok, the other plug on the rr is ok, there is black soot on everything but i wiped it all off and that was that.

i charged up the battery(already tested it at auto zone and its good) go back, pop it in, leave the rr completely disconnected and start it and its fine, connect the rr to the main harness(no stator connected) and it runs fine. I have not had a chance yet to test resistance on the stator wires or the voltage output on the wires either(it started pouring rain when i was about do get to that).

I have been reading and all of the other cases that i have read so far have been as simple replace rr and stator and then good to go. Welp, done did that. Now im still looking into it, could be the rotor, some other electrical part, possibly just a crap stator, or something else that i have not even thought about so far. I want to get the question out here and see if anyone has any experience working with this kind of thing, its a first for me. Sorry for such a long story, Thanks in advance for any help!

 

Dude, you gotta ohm out the wires, they maybe shorted to ground somewhere. If it did the same thing that the OEM did it's not the stator. When you see smoke like that it's a dead short, you should be able to find it.Did you do anything to the bike before? anything? i got 33,000 miles On mine and it runs like the day I brought it home!
Check your wiring.

 

as for doing anythign to the bike before, I bought it like the picture below on the left and it now looks like the picture on the right, so you could say i did some things to it lol...... but it ran fine for three months after i did all of that to it and then one day with absolutely no change since i had put it all together, it just went, white smoke and toast.

I replaced the entire main harness and it made no difference. The resistance(ohm less between .1 and 1, they were all about .3-.4) checks out on all the wires, i have not been able to test the voltage across the terminals with the bike running yet, going to rig it up tomorrow probably and test that out. There is no battery leakage, which usually means, not always, that there is no short to ground.

 

update: I have a short somewhere and cant find it, this is probably what is drawing power and making the wires melt. going to be short to try to get it all posted.

Good stator, Good R/R, Good battery, new main and sub harnesses, good gauge cluster(three of them), When i test for battery leakage it get 1.2mA so there is a short, went through and unplugged every plug and re-tested for short, when i unplug the gauges the short is gone, if i take out the clock fuse short is gone, unplug the four prong plug that goes to starter relay short is gone, other than that nothing changes. Green/red wire is what goes to the Gauges and is also the wire that gets power from the clock fuse, it goes to the fan relay(all relays are good, i have three sets of them) I traced out all the wires on the wiring diagram and no help, no obvious shorts in any of the harnesses or electrical components.

ECU?