GIO X31

[450-WheelieBoyz]

Whats happened/what ive done

- Burnt starter wire
- Everything is loose ! <-- LOCTITE the s**t out of everything
- Opened up the air box!


Starter wire:
The small green wire fried itself completely, i replaced it with a bigger gauge wire worked fine for a while. Upon leaving yesterday i BELIEVE that the fuse blew because all i hear when i push the starter button ( CLICK-CLICK) <--- Upon further inspection the fuse was fine. The wire heated up, melted and shorted on the bike frame. Should i have rewired the small gauge green wires completly? i simply replaced the damaged part...
(The thread about burnt starter wire repair) the guy doesnt really specify if he replaced everything or just the damaged portion..




Shot at 2012-08-13


Shot at 2012-08-13


Shot at 2012-08-13


Im new to the forum, this is my first dirt bike, ive had a few scooters yamaha bws'r .... Thanks in advance guys

[450-WheelieBoyz]

***the two green wires are spliced into the big blue wire that you can only see in the next picture...

any help would be apriciated, pictures, diagrams and videos would also be alot of help

[450-WheelieBoyz]

any help at all...really

thanks

[katoranger]

A click could be the starter relay. Upgrading the ground wire was a good idea.

[450-WheelieBoyz]

i did what i thought was best... but was that enough?

should i have replaced/upgrade the wire gauge all the the way to the starter and cdi?


thanks katoranger

[MICRider]

If your getting a click it means the fuse is probably ok, if it was shot you wouldn't hear anything. On some of the GIO's the wiring/charging systems leave a lot to be desired... My GIO Beast had a tendency to kill it's battery overnight, some sort of a small current draw from something. I used to unhook the negative terminal when I was done using it. I would try charging your battery and see if it turns over, I'm guessing it might just be a dead battery.

[katoranger]

Check all the connections from the battery to the starter. A click usually indicates a bad starter relay or a weak battery. Both are known to go bad out of the box on China bikes.

[FastDoc]

The new motor I put in the Dirt Rat had a bad solenoid.

[450-WheelieBoyz]

thanks guys,

yesterday inspected why the starter wasnt working AND ... the wire melted and shorted on the frame...
i replaced it once again,now im scared to use my starter, if this problem persist i will simply remove the battery and have it as a kick start only.


After playing around with the idle a pit i got the bike running A1 top shape, wow she really pulls. seriously i was impressed by this china-bike

soon i will post a thread with my proposed list of mods i would like to do over the winter to get some feedback

[katoranger]

Is the wire melting from exhaust heat or overload? Maybe the starter is bad and causing too much draw.

[450-WheelieBoyz]

defenitely not melting due to exhaust, overload forsure.
can someone who has had similar problem post some pictures or a breakdown of what happened and what they did to fix it? the thread on this forum the guy says "trace the wires"

can anyone add some clarity to this situation?

[450-WheelieBoyz]

whats the solution is the starter is drawing to much juice?

[katoranger]

The electric motor is going to draw so many amps. The guage of wire feeding it need to be appropriate to handle the load. Poor ground can cause this issue. Bad starter too. Connections at the terminals on the battery, solenoid, starter. Weak battery.

Make sure that the ground connections are good. Possibly add additional grounds from battery to frame. Engine to frame. I have also seen the wire from the starter to the solenoid be pretty light guage.

[Jonny]

I threw mine on the ammeter a few weeks ago when I replaced my battery. The starter draws around 30 amperes. The wire is nowhere near large enough to handle this current but, they use it relying on the fact that you will usually only push the button down for about 2 seconds.
Mine starts that easily but the wire still gets pretty warm if not super hot which softens the insulation.

I expect to see many more threads or replies by people having cooked wires. One issue I had while tinkering with my electrical was the prong bending inside the connectors so I had no juice flowing at all until I found the trouble.

Replace all your wires carrying high current. Any of us that haven't melted theirs are just lucky. It may take 2 weeks, 2 years or 12 but it's still luck keeping the insulation from melting off.

[katoranger]

I upgraded a couple with ones from riding mowers. Much heavier wire and I already had it.