Today I brought home my electrical equipment from work=======I bypassed the melted ground wire plug near the battery=====I instantly noticed the bike was back to slow cranking=====I then performed voltage drop testing and found 3.3volt drop at the starter motor housing=====MEANING the starter isnt grounded to the engine case properly OR the engine case ground is corrded behind the bolt===I can see the main ground wire===I cannot wiggle it or see any obvious corrosion====SO===I ran a new wire from the top starter bolt on the left hand side of the bike====straight to the battery===I then re-measured my voltage drop and found .30volts (this testing was done while the engine was cranking as well as when I found 3.3volts)which is acceptable in my industry====.50volts on a loaded(cranking)starting system====I didnt bring home a socket set with wobbley sockets or I could reach the main engine ground wire and verify its tight or not====wednesday I am going to ride the bike to work and probably build a new ground cable for the engine and accessories====and then bolt it up to the same place====the last thing I want is for people to look at this bike and notice a cheesy wiring repair====I want the bike to be factory---and I can do that at work============anyways====keep my screenname in mind and when any of YOU fellow KLX'rs have a electrical issue====I might be able to help====I do automotive electrical/electronic work====and 12volts DC is the same no matter what the 12 volt system is in====I also was able to find an 06/07 klx250s wiring diagram online for free ==========and just to prove how my luck works=======it was 68F friday==saturday70F---sunday 75F degrees outside and sunny======today===THE SECOND my bike was fixed======the rain started----------

 

Good troubleshooting. glad you found the issue.

 

Disimiliar metals, differant corrosion times and reactions and most people were taught electrical theory, not fact. Flows from negative to positive.