Hot wires issue By choicemopeds (Read 514 times)

[choicemopeds]

I confess -- I'd forgotten about this forum. And, when my google search brought me here I found I've been a member. I posted the following to another forum (2+ years since I had to use the forum) and little help with this issue. Bashan's post has already given me some ideas I am going to try once I send this.

Soooo -- I am seeking some help with a 50cc TaoTao ATM wiring issue.

Customer says the seller will not help.  He brings the scooter in stating it will not start.  It has 750 km on it, ran fine the first 500 then he could only kick start it.  We find the fuse wire melted at the battery and all the wires just below the ignition connection melted and fuse blown.  So -  we electrical taped the wires and they still heat up  (key on 20 seconds).   We've tried a new ignition with same results.  Battery is 12.5volts. 

The mechanic's thought is he needs a new wiring harness.   But - I am wondering if it's some component.  If so, I see us just melting the new harness.

Please tell me what you would try.

[jct842]

If it was me I would find the problem before replacing the harness. And IT IS probably the problem. Would be a shame to install a new one and have it smoke. Looking along the router it takes any rough or sharp looking metal near it would be suspect.

If you lift the grounds one at a time and just tap the fuse wire to the battery looking for a spark might give clues. having an amp meter that has got a big enough range would be helpful. Cutting open the wrap on the harness will eventually lead to a short but the short you find may have been caused by the wires melting due to another short. Test the starter and solenoid to be sure they are ok, a temp jumper to solenoid with original wires removed, same directly to the starter.

As an example take the harness apart half way and should you find no damage you have narrowed it down somewhat.

There are generic wiring diagrams in the library to guide you. IF you are not well versed in electricity you can still find the problem with a little common sense.


The stator and regulator can be isolated and the scooter could be kick started so that you could measure voltage to be sure they are in good shape. Opening the wrap in many places might give you a direction to start looking

[cyborg]

I agree with a wire in the original harness rubbed thru to ground,,,nowwithemelted issue I would be suspect of trying anything till you cut back all the harness wrap and find out if any of the wire have melted together,,, once you isolate the problem then I would change the harness,, I wouldn't want to smoke a new harness and have to start all over again

[tvnacman]

I have seen the wires on the ignition switch burn together. unplugging the ignition switch will isolate it.

John