91 VFR electrical problems.

So a while back I posted but due to work and such I never actaully worked on my bike.

So about a month ago I was riding my 91 when I saw the fuel meter was on low so I got some gas. I pulled in hit kill switch took the keys out and open the tank. I filled up put the key into the ignition turned the key and nothing. no lights no camera no action.

I reaplaced all the fuses, because when I first got the bike the majority of them were blown. and that wasn't the problem.

Took out the alternator and that was fried. I have a new one in the mail,

But it still doesn't explain why the lights won't come on. I know that the alternator is not nessecary for lights to turn on due to the fact that I tested the theory with my 87 vfr.

Here's where I think there might be some trouble spots maybe.
1) the plug to my rectifier is slightly charred, I would of never noticed if I hadn't un plugged it to test the rectifier. (also I tested the rectifier and it was 100%)

2) alternator burnt out like it's all black. but the plug where it connects it fine

3) The switch assembly (or whatever it's called) that holds the main fuse and goes from battery to starter looks like it's been melted slightly.

4) this one is hard to explain. sometimes (when my bike was running) I would turn the key to the on position and no lights would come on. I could turn on my radiator fan though (because i have a manual switch) IF i so much as breathed on it and turned it counter-clockwise then the lights would come on.

There are no more wire harness's on my normal site (partzilla) so Idk where else to go.

Alternator gets here at 5 today.

Any and all help is great thanks!

 

If any of the three yellow wire touched from your stator, your screwed! Fact that the fuse block has temperature issues means bigger and meaner things. Dollars to donuts, your starter relay found near the battery is burnt too. Check and keep us posted.

 

SOOOOOOOOOO I found the problem, but first since I had to go through 2 hours of testing every wire on the wire harness I will make a brief story of what I did that way you can feel my pain a little as well lol

I tested all wires on the harness there are literally about 400 holes from the voltmeter needles around the harness.

I touched the starter to the batter (BIG sparks and it turned luckily)

I started checking all the plugs again. took the front fairing off (to find the previous owner zip tied the headlight on, put that on the list of things to fix on this crazy thing)

I thought hmmm maybe it's the key. I unplugged the key stuck a 40 amp fuse in the two leads and all lights came on and I just took it for a ride to o'reilly.

Now I have a 30 amp switch connected to the key leads and I'll have to figure out how to take the key assembly off.

 

may be a tamper proof torx or a regular one, 27? or maybe 30? You should fill in those holes with silicon as you don't want to get wires wet like that.