Hey everyone so today was the first day we had some warm weather up here in Wisconsin... So I fired the old crotch rocket and went for a ride... (For the First time in 3-4 weeks) I putted around town until it warmed up then I hit the interstate to open her up and clear her up after the little spell of sitting. So I ride about 6 miles to the closest exit turn around and head back, As soon as I gear down to get off at my exit, I geared down to 4th gear squeezed in the clutch and started braking but as soon as I squeezed the clutch in the bike just shut off! So I released the clutch lever and started back up but just kept spitting and sputtering my first thought was oh **** I didnt even check the gas so I reach down flip it on reserve while popping backfiring and jolting me on the exit ramp. I made about another mile and the bike just quit so of course I opened the tank cap and had almost a full tank guess I filled up before I parked her. Now I always carry a backpack with me with a bunch of random tools just in case something like this was to happen. So I tried cranking her over and got nothing then I noticed my headlight wasnt on? then I hit the brake while kneeling and looking at the brake light and nothing. So I pull the seat off and I had a volt meter in my backpack the battery read 12.7 volts so I cracked the bolts on the battery and re-tightened just to make sure it wasnt a bad connection and still nothing. so next I checked the fuses they where all good. So I started looking and feeling around the wiring harness and the battery was RED HOT couldnt even touch it! And the Brain box was super hot as well but it was next to the battery so Im not sure if it was just hot from the battery or what. Does anyone know what they think might be the issue? Voltage regulator, CDI Box or what I just want to make sure before I go replacing all the electronics thanks in advanced!!!

 

Reg rec fried or a short somewhere where it bypasses the main fuses. My bet is the latter.

 

Hi bud,

Go right back to basics and investigate each part of the electrical system to begin with. So the battery: its age and what charge it will hold when unused over a few days.

If the battery's good then charge it fully and see if the electrical system turns on.

If it does then confirm you have spark. If not check your fuses and take it from there.

Forgive me if you've done this stuff already. I suspect that your battery's gone south due to lack of use and this has caused the trouble.

Let us know how you get on.
Roger

 

Battery is only 2 months old and it holds a full charge I threw an old lawn mower battery on it just to see if any of the lights would come on and nothing! Any other suggestions?

 

I would bet its shorting somewhere in the wiring. The battery and CDI box shouldn't be so hot that you can't touch them

 

So with the good battery on use a mutimeter to go through the ignition circuit to find out how far along it the voltage goes. Check across components for continuity. The service manual will be really good for diagnosing in this way.