Any ideas !!

Don't know what year you have.
Here is one from a 97:
http://tomradde.com/xt225/styled/index.html

The one in your photo, looks like it was wraped in Duct Tape.

Know many other parts are the same.
Don't know, what years on the Wire Harness, are compatible.
Others here, who have, 'been their-done that', will know.

So find out, and give me a yell,  Shipping would just be 6.00 Post Office PM. (In the USA)

Oh, and on the wiring you have, on my screen, it looked, 'silverery', but I took one of you photos and blew it up, and now it looks like the standard black elect tape, (which this one has).

What would cause this harness to fry like this?

When did you put the battery in?
Did you take the seat off?

verslagen1 wrote on 03/15/15 at 14:21:31:


Exactly. One blown fuse can be attributed to many things. Back-to-back blown fuses only points to one thing, a short somewhere. As a pilot I am trained to only try one reset (after a cool off period). If upon the the reset the circuit pops, then that circuit remains inop until it can be run down.

You may have had a very simple problem, like a single short due to a pinched wire. Now you have a fried harness due to arcing. You're lucky that you didn't have a bike-bbq.

You'll know better next time.

I spent part of the morning pissed off because I fried the wiring harness and I didn't want to pay for another one.   Looking at the harness closely, I think I can tell where the wires were pinched from the seat.  Out of desperation, I pulled the harness off the bike and slowly started digging into the thing to see if there was anyway it could be salvaged.   At first, I had very little hope because it looked bad but I started at one end and slowly separated all the wires.   They were melted together good. My son and I spent about three hours trying to piece this thing back together.    Finally we threw it back on the bike and it started right up.  I had my doubts but I'm glad it's running.  Lesson learned.