Why has the fuse not blown? If the wire is getting this hot then the fuse if correctly sized should blow to prevent a burnout. You failed to give the year of the bike so cannot help any further. Check all fuses for correct rating. Have you installed extra electrical equipment incorrectly? Overload on the system perhaps? Unless you understand auto electrics and have access to a DC clamp meter to check all circuits then I sugest you bring your bike to a dealer before it goes up in smoke!
SOURCE: cbr 600 getting hot!
What you are describing sounds exactly like a loose connection. If you haven''t done this already, disconnect the two connectors for the R/R and check the female spade lugs to see if they are loose. You can buy a male spade lug to push into the female to check for tightness. If it''s loose then use a set of needle nose pliers to crimp the female spade lugs a little. Just because they plug in to each other does not mean that you are getting a tight connection. Also, how do you know they were not loose?
SOURCE: starter will not engage-soleniod just clicks-
I had this problem last year. I was told by a reputable Yamaha service technician that I could "jump" the leads on the solenoid to unstick it. It worked. However, in retrospect, I wish I would have just replaced the solenoid, given that it is a relatively cheap component (~$40 new). Since then, I had the sticking and clicking problem again this past March right at the beginning of the season, and during my attempt to repeat the success, I shorted out the bike because I got careless about what my disconnected wires touched on the bike. Shame on me. So I'd recommend replacing the solenoid.
SOURCE: Kawasaki zx7 won't start
Hi. I had the same issues as what your saying. What we found was that the leads are a screw in into the spark plug cap. Unscrew the leads to the cap, trim the ends off by a mm or 2 and re-screw back into cap that goes onto spark plug. There renown for pulling out and giving weak or no spark.
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