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I bet it was the three wire connector that melted going down to your stator correct?

if your voltage regulator checks out O.K then the heat that melted the plug was caused by the connection between the male and female connectors inside of the plug. If you look at the wires they look silver and not copper any more because the heat.. Just cut the wire back 3-4" or so and use new 12 or 14gauge copper stranded wire and solder it all back together make sure to shrink rap the wires real good and this should be it.. the regulators get hot so don't get scared if it gets warm the wires that you fixed should not get hot now............ Be safe ride fast.....

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Q: Why would a stator and voltage regulator be melting and burning up on my 2000 kawasaki zx12r?
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