I have a 2000 gsxr 750 that needs is having electrical issue. I was riding a couple nights ago when the bike shut off and wouldn't turn back on. There was a strong burning electrical smell and the main 30 amp fuse was blown.
I put in a new fuse and it immediately blew. I checked wires running to the relay with the fuse and reconnected the battery. Another fuse blew, instead of instantly the bike was able to turn for a split second and I saw smoke coming from the regulator/rectifier
The connector coming from the stator into the rectifier is melted and had to be pried apart.
The 3 yellow wires going into the stator have small marks in the sheathing but none of them are touching eachother.
The day before this happened the bike had an issue starting, it would crank once then shut off and the display would go from showing Trip 1 to the showing the odometer, after the bike cooled off for a couple hours it fired up no issue but wouldn't start the next morning from a low battery so I grabbed the battery from my other bike and it worked.
I purchased a new regulator/rectifier but will need new connectors so it can be attached, would it be best to cut off the old connector (stator side) and splice in a new one or is there a different preferred method?
Second question, what would be the biggest culprit of causing this failure? I was hoping to just replace the regulator so I could get back out.
Should I be cracking into the stator and testing it or even replacing those 3 wires?
Any help is appreciated.