Does it really have a starter/alternator combo? I haven't seen anything like that in years. If it were me I would disconnect the wires from the solenoid and touch them together then hit the starter button and see what happens. The solenoid just protects the starter button from high tension wear and one hit won't damage it.
According to the shop manual, it does have a starter/alternator combo. These scoots are "Greek to me" being an old-school Harley dinosaur... LOL!
You're absolutely right about the solenoid only to protect the little pee-wee wired starter button. However, the doggoned solenoid is factory-wired DIRECTLY to the BATTERY. When touching the wires together, the starter spins regardless of use of the starter button. Touching the wires together, or simply shorting across the terminals always engages the starter... Even if there's NO juice to anything else.
The only diagnosis I performed so far was to check the solenoid with a resistance meter, and it definitely is "stuck" in the start position. So IT is verified no-good... After only a dozen starts!
I'm still at a loss as to why the battery got red-hot. I truly think it shorted out a cell or two. It's seven years old and I should have replaced it... But it was always reliable and held a charge fine, so I got cheap... LOL!
When the engine started for that last ride, all seemed normal. I could plainly hear the starter-clutch disengage as soon as the motor fired up. Red "battery" light went out as usual, showing good charge. Then minutes later, the red-light came on and the motor died in seconds, the starter feebly trying to engage until the battery dropped below enough voltage to do anything.
Currently, the weather is just AWFUL, keeping me from working on it.
I still can't imagine a fuse NOT being blown, or some wires being fried. I think all the fuses are in one place by the battery. I need to be sure there are not others hid away some place... Sure would be nice if a new FUSE, and new SOLENOID and new BATTERY would fix the old Mouse, but... I'm not holding my breath...
When it warms up and quits raining, I'll get back to work and see if I can find the gremlin...
I also realize even the shop manual is not really clear about the alternator/starter combo. The English translation is little better than Chinese manuals... It's entirely possible that the charging takes place "elsewhere" on the motor.
I'll keep posting as I learn more... It seems most Kymcos of various models use a similar system to my old Grandvista, and I may learn some good stuff to pass on to others.
Stay warm!
Leo
