GIO X31
 

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..



http://img705.imageshack.us/img705/3...cture006ma.jpg
Shot at 2012-08-13

http://img36.imageshack.us/img36/7084/picture005kbf.jpg
Shot at 2012-08-13

http://img259.imageshack.us/img259/9...cture007qe.jpg
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Im new to the forum, this is my first dirt bike, ive had a few scooters yamaha bws'r .... Thanks in advance guys

***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

any help at all...really

thanks

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

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

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.

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.

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

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

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

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?

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

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.

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.

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

the simplest and cheapest "solution" is to kick start it from now on
and only use the starter on occasion i guess.

i had upgrade the wire gauge, but then it melted and shorted out against the bike frame.

so i put an even bigger gauge wire ( wrapped in an even bigger gauge wire's insulator ) and its not tied down to the frame this time.
hope it doesnt melt ever again.

if it happens one more time im calling my electrician friend and im gonna let him have his way with her.

i guess i cant expect too much from a 500$ dirtbike right?... RIGHT

I guess i cant expect too much from a 500$ dirtbike right?... RIGHT

You can expect it to start and not melt.

so once again my starter is not working...im stripping down the bike next weekend upgrading as much parts as possible. i would really like to re-do the starter ground once and for all.....but how?

hard to kickstart...starter problems.. yayyy ;(

Just curious, are all the other connections clean and tight? A loose connection can cause increased resistance and that can melt a wire as well.

The other thing would be a bad starter like Kato was saying. The bonus there is that the starter for a china bike is a fraction of the cost of a japanese one... I haven't done a search but they should have them on ebay.

its going down this weekend!

changing fuel lines,bolts and nuts,NGK sparkplug, carb cleaning, Loctite everything, and redo the starter ground once and for all !

i will post pictures sometime next week.
cheers

NO F-ING FUEL FILTER! on a brand new x31....
-added a fuel filter
-clear 3/16 gas lines
-ngk spark plug
-good carb cleaning ( dirty jets, debris, NO FUEL FILER :@ )
-Fixed the burnt starter ground ( 10 gauge wire spliced in, added a ground from the battery to the frame ) WOW - what a difference


Anything i forget?
heres some pics, any suggestions would be great. thanks

http://img560.imageshack.us/img560/2...cture007za.jpg
Shot at 2012-08-27

http://img338.imageshack.us/img338/7...cture006fi.jpg
Shot at 2012-08-27

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http://img694.imageshack.us/img694/7...cture009ak.jpg
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http://img607.imageshack.us/img607/2...cture010ir.jpg
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http://img515.imageshack.us/img515/4...cture011yf.jpg
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http://img109.imageshack.us/img109/333/picture012ib.jpg
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http://img715.imageshack.us/img715/808/picture013c.jpg
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ill will add picture of the new starter ground i did!

cheers!

So that took care of the starter problems? I was guessing it was poor wiring related, my Beast was the same way. Good to see your getting it all sorted out, should be a good bike for you now once you get it all "fine tuned" :)

I think you have covered alot of the prep items.

If you remove the fuel petcock, does it have a filter that is inside the tank? Have you set the valves?

I had my wiring harness melt too(I'm pretty sure it was the same wire). I haven't really been on my X31 much due to a surgery. I emailed GIO to see if they will replace the harness.

everything went smoothly, im very pleased XD
all thats left now is fine tuning and esthetics

NO FILTER WHATSOEVER !!

the starter works atleast 10 times better than before. im really amazed
thanks MICRider!

i will be adding pics soon thanks guys

Have you set the valves?

im not very comfortable taking the engine apart/out .... the bike is brand new
cam ajustments is something ive never done. is it really that important right now? i havent even done my first oil change yet.... is there a thread on shimming valves on a Gio x31 ?

thanks weldy

It's a pretty simple process, and it doesn't involve taking the engine apart. It would be good for you to become comfortable with the procedure, because you should at least check your valves every couple of oil changes. If your valves are too tight, they rob power and wear the valves faster. If they're too loose, they also rob power (and they're really noisy).

It sure beats paying someone to do it.

so all i would need is

-valve shims
- magnet
- feeler gauge
-nail polish
???

if theres a good video on youtube that could help that would be great or a thread please let me know. thanks again

Not sure where you heard about valve shims, but I don't think your bike uses them. You simply need a feeler gauge and some common hand tools. Please show us a pic of the top end of your bike, so we can figure out which procedure you need.

perfect ill take a picture of my engine. its a 250cc OHC zongshen x31 2011

http://img94.imageshack.us/img94/4972/picture007th.jpg
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http://img708.imageshack.us/img708/1...cture006iu.jpg
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http://img155.imageshack.us/img155/2...cture004ew.jpg
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we can see the engine fairly well in these pics

cheers.
thanks weldy!..... i watched a quick video on youtube about valve adjusting thats where i saw the guy use shims.....

Don't think you need shims. Just a couple wrenches and feeler gauges. About 15 minutes of time.

Here's a good tutorial: http://chinariders.net/modules.php?n...ewtopic&t=1655

thanks!

ill adjust the valves this winter, ive maybe rode 100 kms so far this summer.... im doing my first oil change this weekend....

the thread on adjusting the valves was very helpful....doesnt seem very hard at all :)

oil change did the gio some good!
i was very surprised at how dirty the used oil was, i will be doing another oil change shortly. im guessing they used cheap chinese oil and gas the factory rodage/break in.

does any know if these bikes comes brand new with oil in them already??

We've heard rumours that some brands are shipped with fish oil rather than motor oil. I wouldn't be surprised, because I've drained out whatever was in there and refilled with proper oil, and spilled some of the original oil in the process. The so-called fish oil completely dried up and disappeared in the sun. 8O

My gio x31 has a --- KMC 428-128L


a friend of mine gave me two japo chains 428-xxx for yz85 or cr85



how do chain sizes work? 428 in the size? and the second number is the number of links in the chain?

if i go to a local bike shop, can the mecanic make the two chains into one?