only cranks to start, headlight no longer works  By  murkyapricot (Read 1,534 times)

If it would start with the kickstarter but not the electric starter I would start looking for bad wires going from the battery all the way to the starter. 

There's the wire that goes from the battery to the solenoid, then a wire to the starter. Check for urn marks, holes or dents in the insulation on the wires, etc. I just recently replaced my starter wires, they looked mostly good on the outside but were crispy, burnt, and so worn out on the inside that I found parts that were almost completely disconnected from the wires burning up.

If you suspect bad grounding try adding an extra ground wire to the starter. Connect a wire from the bolt that holds the starter on the engine and connect that wire to the frame. Also, connect a wire from the battery to the frame near the battery, and another from the valve cover to the frame as well. I put 12 gauge on all of the above spots for extra grounding, have only been getting better since I've been replacing all the wires. They say the wires that come on these scoots can be of bad quality, and can burn up over time. 

The starter requires the most power out of all the components, I am using 12 gauge for the ground, and 12 gauge for the battery to solenoid connection. It seems the wire from the solenoid to the starter on mine is 14 gauge, it was a wire that came with a replacement starter motor, so I may end up changing it to 12 gauge down the line as well. It is better to be slightly thicker in gauge than it is to be thinner, thinner wires will fry.

As far as the lights, I would check the rectifier, make sure the wires aren't corroded or disconnected. Listen to it while the engine is running, does it make a buzzing noise? Mine made a buzzing noise when it was being overloaded when I had removed the battery and was only using the kick. Maybe a bad ground, trace the ground lines to heck for anything wrong, if you don't see anything you could just add more grounding to the lights and dash and see if that helps or not. 

Is the battery good on your scoot? You may also go ahead and check the stator connections. The yellow wire is for the lights, the white for the charging, but they can take power from each other if one is not giving enough. 

So i looked over the scooter real quick today and the first thing i found was this plug that i couldn't figure out where it's supposed to go

any idea what this is for?
A little tough to see but it's two wires green and white

Hard to tell to comes out of a larger bunch of wires that are all taped together and look like they're heading towards the front end of the scooter

I just read over the GY6 manual to see if it would help, it seems there is only 1 solid white wire. It should be going from the stator to the rectifier. This may be why the scoot started needing kicks and could not get enough power from the battery, the battery may not be charging at all in this scenario which may have put strain on your lighting wires from the stator, because I am told the rectifier will allow the charging system to take some power from the lighting power feed if the charging power isn't enough or vice versa.

There has got to be another connector around there somewhere or at the least a wire or two without a connector end.

it's possible it doesn't connect to anything. my old atm50 had one of those phantom connectors and wondered the same thing. doing a little research i read that many factory's use a generic wire harness and some unused connectors could have been for options your scooter doesn't have. such as an alarm or whatever... anyhow, just saying don't sweat it too much if you can't find the other end.

did you check the fuse? i had a loose fuse awhile ago that killed all power to my starter but i could still kick start.