I was out driving my 250 around and it started smoking right by right leg. Turns out the coil melted and a few of the ground wires melted in the wiring harness, taking out a couple of other wires with it. It looks like it took out the neutral relay as well. I have not tested the starter relay, but that seems to be working because the starter spins. Does anybody have any idea what would have caused this? I am hoping the voltage regulator and cdi was not damaged as well. My other question, has anybody ever purchased one of the aftermarket coils, they are a less than half the cost of the OEM? I am also looking for a used wiring harness if anyone knows of anyone selling one.

 

Looks like the positive cable on the battery, hit the frame and melted the ground wires. Strange that no fuse blew, but took out the coil.

 

power wire in the harness rubbed on a sharp edge. look at harness for a bare spot.

 

Battery cables are not fused. I would repair all wiring before checking to see if something is bad.

 

After digging a little deeper into the wire harness, it looks like alot of the ground wires were damaged. The two wire plug coming out of the voltage regulator arced and blew it out and my CDI is shot as well. Anyone know where I can find a used one, ebay has none. I have rewired all of the ground wires, wondering if I should just get a new/used harness as well. Used parts are hard to find for this model.