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General Category >> Rubber Side Down! >> Elec sys help please!
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Message started by splash07 on 07/21/09 at 19:53:50

Title: Elec sys help please!
Post by splash07 on 07/21/09 at 19:53:50

Here is what happened:

I just finished working on the bike and I had removed the ignitor box. When I was finished and put the box back on the bike I forgot to zip tie it to the bracket. As I rode, the box vibrated loose and was hangin by the wires. The wires were rubbing against the belt and as soon as the belt cut through the first wire the bike died.

My Question:

Can I just buy a new female plug somewhere or do I re-wire the old plug??

Title: Re: Elec sys help please!
Post by justin_o_guy2 on 07/22/09 at 05:26:08

I'd clean up the wounded area, get some heat shrink tubing, splice in any length required to repair any length lost due to the rubbing & just fix your screw up. For the cost of the parts, you can get some soldering equipment.
How many wires are there? If you do have to replace a connector, ever, & you dont want to spend the $$$ for a factory unit, go to a junkyard & get a connector out of a car & splice that in. If its just 3 or 4 wires & you need a flat connector, a trailer connector will work.

Title: Re: Elec sys help please!
Post by dasch on 07/22/09 at 10:25:07

And the "plug" is nothing but a holder for a "regular" small flat connectors! You can do without it too, as long as you know which one goes where. My 5 cents - no need to waste money looking for a stock part. Here:

http://www.facebook.com/photo.php?pid=229897&l=2906942526&id=1071939517

...as you can see, they are all cut & spliced & heat shrink tubed... no problem.

Title: Re: Elec sys help please!
Post by splash07 on 07/23/09 at 21:39:47

Well, I think yall are absolutley right.

Also Why does it look like ther is gravel embedded in the bottom of the ignitor box?

Title: Re: Elec sys help please!
Post by dasch on 07/24/09 at 07:20:33

?? Have you dropped it or something ;)

Might be the anti-slip tape or something, dunno. Mine doesn't have it, I think.

Title: Re: Elec sys help please!
Post by splash07 on 07/25/09 at 17:05:22

If some one could help me I need to know which colored wires correspond to which prongs on the ignitor box. When the plug was cut off by the belt most of the wire insulation went as well.

Title: Re: Elec sys help please!
Post by splash07 on 07/25/09 at 18:35:42

OK, so I got it now. It turned out I had the correct wiring config but I had a blown fuse. New Fuse and we have life. Now If I can just figure out why it wont start.

Title: Re: Elec sys help please!
Post by dasch on 07/25/09 at 23:26:14

Check that link I posted above. Make sure all contacts are clean and tight. I had problems when one of them was apparently loose.
Perhaps you shorted it when the belt cut through. Check fuses first. And make sure you jump the battery to a car during testing. Lots of testing (cranking) will kill yours quickly.

Title: Re: Elec sys help please!
Post by justin_o_guy2 on 07/26/09 at 03:35:25

& they can be strong enough to spin the motor over, but not provide a strong enough spark to crank.