Question for Ally or JR (Finalized) (Updated 4-2-2015) By insanetexan (Read 3,970 times)

[insanetexan]

Sorry for the long delay in coming back with an update. Between the weather and the short working time I have during the day I have finally finished this project.

Here is what has been done;

First of all I opened all the wiring and checked each and every wire along the scooter and where there was a splice I cut and re-spliced it together and soldered each one.

Second I ran all new 14 Gauge wire for the four main wire runs the length of the Scooter, Red, Black, Yellow and Green.

Third I removed the new Stator I had previously installed from the last time I posted and replaced the wires from the Stator out to the R/R plug with 16 Gauge wire and soldered those in place.

Fourth I added the new R/R.

Now somewhere along doing all that it seems to have fixed the problem of over heating the wires and melting the connectors. Now I can run the Scooter and the connections that were melting before are just barely getting warm.

The voltage meter that I have installed is showing that I am now maintaining a steady 13 to 13.5 volts even with the radiator fan running.

Oh Happy Day

P.S. lets see how long this fix lasts.

[ellpee]

Congratulations for your perseverance. But as to those stator wires, you went to 16ga? You mean they were even smaller than that before? Seems to me mine are 14ga, maybe even 12. (Smaller being larger ....)

[insanetexan]

The Stator wires running up from the Stator to the R/R on mine were around a 24 Gauge. They were so small my wire strippers wouldn't work on them.
I pretty much think the wires are a big problem on the Stator and making them to overheat.

In a scenario it would be like using a 220 volt electric stove and running 14 or 16 Gauge wire to operate it instead of the minimum requirement of 10 Gauge. The smaller the wire the more they will overheat when used to run a lot of voltage.

I myself didn't realize the wires on the stator were that small till I was gonna splice into where they melted.

[ellpee]

Wow, I'm fairly sure mine, on the CFMoto engine, were at least 16, probably 14.