Electrical Woes By jodysbms (Read 738 times)

[jodysbms]

2008 BMS Heritage 150 Scooter: 3200 miles, GY6. This year the scooter started acting up. It would run for anywhere from 15 minutes to around an hour then die. Sometimes it would start right up, other times it had to sit for a while. Up to over night. Found one of the wires from the stater, at the plug, burned. I replaced the stater with similar, 12 pole along with the fly wheel. 3 days later the same thing started happening. I found that if I took a continuity probe and check the wires on the CDI, it would kill the engine. I then just used a small awl and just applied light pressure to one wire it would kill the engine. I replace the CDI and coil. When I cranked the engine, i could small electrical burning. No, it did not start. Installed old CDI and it did run. Check voltage at regulator, it showed 7.5 volts on each leg from stater. Output was 15.75 volts! I replaced regulator and input went to 12.5 volt on each wire from stator and output is now 13.5 volt. Downside, the wires are getting very warm!! Where do I go from here? Use a smaller stator? 6 or 8 pole? Also have just installed new battery.

[tvnacman]

ground!!!!!!!!!!!!!

[felliott]

If the battery is low on charge the wires will be warm. Make sure all grounds are clean and tight as mention above.

[Bashan]

A smaller stator is not a fix for anything, don't swap one out. If the 13.5 volts is your charging reading on the red wire that's good. Is it the red wire that's getting warm and is that your only concern at this point?

[jodysbms]

Seems mainly the stater wires. With the old stater, they did not but also shows less voltage

[jodysbms]

So I cleaned at every location there was a ground strap. Found rusty bolts and shiney paint. Sanded off the paint checked terminals and reassembled. Stater wires got warm, but you can still hold them. Left it running for about 15-20 minutes with no problems. Started replacing vacuum lines, noticed a lot of cracks at every bend. Also replaced the fuel line and filter. Now it became difficult to start. Volt meter at soleniod showed a drop to 8.5 volts when cranking. Battery seemed very weak. Voltage showed 12.5 but don't know the amperage. Put it on the battery tender, red light came on showing it needed charging. I'll let it charge overnight. I might have to put old regulator back on? Don't understand the voltage with the old one. Input 7.5 each leg of stater, output, red wire, 15.75. New regulator is 12.5 input, 13.5 output. I would think the new is correct, but why will it not keep battery charged? I removed the alarm/remote starter Saturday morning.

[Alleyoop]

They will usually not charge at IDLE, especially if you have your headlights on they draw a lot of juice. Connect your volt meter to the battery and rev the motor up to around 3-4k and see if the battery volts then starts to climb. It should start to climb above 13V, if you get 14.5 that is excellent.
Alleyoop

[sprocket]

Check the filter is in the line the right way..reversing it is a common mistake and it won't run well if backwards..

[jodysbms]

Everything settled down. Checked voltage, 14.5 with engine off. Went for a 15-20 minute ride, checked voltage engine off 10. Put it away as I was ready to burn it (LOL). Put trickle charger on it over night. Checked battery in my car, 14.5v. Checked battery in the meter, replaced it. Now car battery is 12.5! This morning checked scooter, 12.5. Rode it same route as before, checked 12.5, engine off. Realized check meter before using!! Battery in meter was over 5 years old!! MY BAD!! Scooter has new CDI, coil and battery. The new regulator was not putting out enough voltage, 11.5-12. The old one is running right, 12.5-13!!!

[Alleyoop]

Great, when they do not charge it is either the R/R or the stator, good it was just the plug and play R/R.
Alleyoop it was just the