Electrical Mis-connection problems - resolved

[buckeyescoot]

Hi all -

Really need your help on this one. Replaced the Stator on my Roketa Bali 250 over the weekend. Process was slow (for me) but the scooter started up with no oil or antifreeze leaks.

Tested the VAC coming off the stator and noticed it was still low 34 VAC/34VAC/0 VAC) from the three feeds.

Decided to drive it for a day or two. Monday I decided to remove the outer covers again, record the VAC and get an e-mail off to all new sports to discuss a new stator again.

I also was going to double check all the cable connectors just for good measure. Instead of doing one at a time, I disconnected them all then reconnected. This is were the problems began. I noticed that three sets of 2 prong connector that needed to be reconnected. One set had matching cable color codes the other two did not. When I plug what I though was correct, the scooter would crank and crank but not turn over.

Tried a different combination on the 2 prong plugs and now no electrical "signs" anywhere on the scooter, no break lights, no horn, no dash activity (fuel needle)

Tried other combinations again and still nothing. Checked the in-line fuse on the battery and the fuses in the fuse box. All look good!

Any thoughts and what to try next. Could I have damaged any electrical components with the mis-connections?

Help!

Joe (buckeyescoot)

[Gary]

Joe -
Sorry to hear this. When you checked the fuses, did you verify that the individual connectors to the fuses were actually connected to the contacts on the fuses? Sometimes the connectors push out of their seats at the bottom of the fuse box and thus don't make contact. I had this happen once.

Its also too bad and strange that the replacement stator shows 0 volts on one leg. Was it a new stator? (Allnew sent me a replacement [which I wound up not using], but it clearly was a used one, not a new one.) Did you measure the resistance of the coils? The resistance should be about 0.9 ohms across each leg.

If you don't get the scooter going in the next day or so, send me a personal message and I will take photos of my wiring; maybe that will help make sure you get the right connectors lined up.

[buckeyescoot]

Hi Gary -

I did check the fuse blades to insure that they were in contact with the contact points in the fuse box (twice). I may take you up on the pics on your wiring. DO you have a good wiring diagram? It sounds like the Viva 250 and the Roketa 250 are very similar.

I have disassembled the wiring harness so that I can physically trace the wires from Point A to Point B on the three 2 prong connectors to see where they go and use the wiring diagram ( oh boy) to work backward to see where on the wiring diagram the connection is supposed to be.

I also am going to trace the electrical voltage down the lines from the battery to the first connection points (starter relay for the main red positive line, the wiring harness connection point for the red 16 gage, 7 amp in-line fused line and the green grounds to volt regulator bolt to see if that looks okay.

I did redo the green wire ground connections in the wiring harness as a few looked like they were connected by just a thread of wire. (Six ground lines coming together with a single green 16 gage wire running off to frame ground at the volt regulator bolt.

With no lights or electrical functions at all now, I am concerned that I burned up some component like the volt regulator.

The Stator I got from Allnewsports looked like it had been reworked. The physical 18-point coil heads ( not sure what those are called) looked used but the windings and the three yellow feeds looked new. FYI, you will need a gasket if you do the stator switch.

I'll keep everyone in the loop on what I find out. It may be this weekend as my pre-teen children are in fall sports and practice seems to be every week night then homework. Also I work for a College here in Cincinnati so when the students return, which they just did, things get a little crazy so I am not always home in time to do a little scooter tinkering and family time as well!

Joe

[buckeyescoot]

Hi All - update

Started checking the continuity on the wire and cable this morning before work. When I checked the 16 gage wire with the in-line fuse (that I just replaced) there was no continuity! Replaced the fuse and the scooter fired right up. ;D The fuse physically looked good, not burned or broken so I did not think to check it with a multimeter for continuity. I did check the rest of my spare fuses so I don't get caught in the future with this issue.

(I did do a very detailed wire trace with an opened wiring harness to confirm with the wiring diagram that all the connectors were connected correctly and going to the right component all Sunday afternoon. I am assuming that this process got me reconnected correctly but with the fuse blown I was assuming the worst)

I will re-wrap the wiring harness and cable tie it back to the frame and put the covers back sometime this week.

Gary - Thanks for you help!

Joe (buckeyescoot)

[Gary]

Joe,
Great news.
Gary

[jonnypm002]

hey guys i need help with my rocketa bali250...i charge my battery and also tried buying another one....but every couple days the battery is dying....so im stuck...does anyone have any answers to why this is happening or some info that could help me find it...

[Glennby]

do you have an alarm system?,or a radio?.they will drain you battery.so you might want to start there.turn your radio off if so equiped.as for the alarm,try and disconect it.and see if your battery stays charged.

[Gary]

Johnny,
It could also be that your charging system is not working. There are many good posts on this.

An easy check is to start your scooter up, then disconnect the battery. If the scooter keeps running, the charging system is working and the problem could be a short or the radio or the alarm. On the other hand if the scooter dies when you disconnect the battery, then the charging system isn't working. There could be several reasons for this. In my case the problem was a defective $10 part called the resistor heat sink diode. Replacing the diode solved my charging problem and I'm now one happy scoot dawg. Check some of my posts and you'll find photos etc.
Gary

[scooterollie]

From the posts about diode failures, sounds like the Chinese diodes aren't any better quality than the Chinese fuses!!! (LOL)

[buckeyescoot]

Hi Everyone -

The fuse that failed was one purchased from a boat marina supply here in Cincinnati - Anchor Products, Inc. 7 amp fuses. I probably bang it around as I was testing the scooter charging system after replacing the stator.

I am just glad it wasn't something more expenses then a fuse.

Joe

[jonnypm002]

hey guys i managed to figure that i need to replace the stator and rectifire on my bali 250....does anyone know where i can get the parts...mechanic said any 250cc liquid cooled engine would work

[scooterollie]

jonny;
In speaking with a dealer who sells CFMoto products recently, he said that CFMoto upgraded the stator to, I think he said, a larger one. I didn't quiz him about the details because our conversation was really about a different engine make and a different point. You may want to check that out. His business is HH Motor Sports in Ohio, ph # 513-753-0888. Ask for "Joe".

[Gary]

Johnny,
Check the scooters georgia web site under Tank 250 parts: www.scootersgeorgia.com/tascpa.html. They've given me great service in the past. Note that the rectifier is listed as a 'resistor/heat sink.' They also carry the stator, but you might call and ask if there is a "new" stator as ollie suggested.

[fulltimerart]

If you shut your engine off by putting the side stand down, make sure you turn the key off afterwards---this will kill a battery quick. Art