2003 450 burnt wiring

If you can find a good used harness for a decent price I would probably want to replace the harness. But if it were me, and just because I like projects and I'm a tad on the frugal side, I would probably pull the harness and fix the wiring. Just more of a hassle then anything to replace a large section of wire(s). Was it melted due to heat, or a short in the wiring?

I will drop this bit of advice....Grounds!!....they are so much more important then most people realize. Poor grounds will/can cause all kinds of issues, and melted wiring as well. I pull, sand, clean and re-install all my grounds, battery, body etc....on my vehicles, sleds, quads, cars, trucks, tractors etc...once a year, two at the most.

That innocent little ground attach point can be the cause of many problems, ever had that electrical problem that you kept chasing your tail over? Grounds should be the 1st thing to look at, a lot of grounds rely on thread to thread contact not the flat of the lead connector to get the earth, between the threads is an air gap that gap can corrode & cause a bad earth(rant over, I hate earth's)
So 10x agree with thrashingcows.

Not sure but I think the coil pack has to ground through the attaching points to the frame, so if that/those grounds went bad it could be why the coil wiring cooked?

Found coil ground wire melted to a connector about in the middle of the tank right side, replaced that wire with solder connections and coil. Wire melted because it was trying qto find a ground. Ground from battery to engine was corroded at the engine and the CDI box had to be replaced also. It's up and running again.

fitter562 said:

Found coil ground wire melted to a connector about in the middle of the tank right side, replaced that wire with solder connections and coil. Wire melted because it was trying qto find a ground. Ground from battery to engine was corroded at the engine and the CDI box had to be replaced also. It's up and running again.

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Thanks for the update....darn grounds huh! I redo all my grounds on most of my/our vehicles every year or two, and adding additional grounds is never a bad thing either. :wink2: