ugh now it wont start!  By  lain (Read 2,802 times)

I may have found the problem, but unsure until I try a couple things out. I basically pulled out the wire for the batter-solenoid connection, and the wire itself sounds like it's all crinkly like as if you were smushing a plastic bag in your hand. Now I am no pro but I'm sure wires do not make noise. Also noticing what looks like burn marks on the outside, but if I wipe the wire off it looks mostly clean with some dents in it. I am unsure as to the gauge of the wire, I only have 12 and 18 right now, so I am going to attempt to hook it up with some 12 gauge and see if it starts.

I already added an extra grounding wire to the starter motor and had no new results.

Looking at the wire, it looks to be maybe 10 or 12 gauge itself (thw wire from battery to solenoid), the wire that connects the solenoid to the starter looks to be 14 or 16 gauge. Mind you I am just eyeing these out while holding my wire stripper next tot he wires to reference girth of wire core. 

My solenoid still looks nice, some minor rust, but I'll brush that off with a brass wire brush.

Not sure if this is your problem but it sounds similar ramblinman maybe you can follow what I'm doing here and see if it works for you.

so the battery to the solenoid is actually 12 gauge, which according to the amps/volt/gauge chart is right on. I had a spare positive wire to the starter from when I replaced my starter, it appears to be 16 gauge. I replaced those wires and it starts up with minimal effort. I literally don't have enough time to take my hand off the starter button before it starts if I try to tap the starter button now.

The lowest a wire on a scooter should go is 10, you aren't dealing with 300+amps, no need for 6 gauge. 10-12 gauge is the highest on a scooter, and the highest gauge is the starter.

So after rewiring the starter, I went for a ride last night. The lights were actually useful, not as bright as they were before, but useful nonetheless! Ontop of the easy starting and lights working better, the low end seems better and more responsive as well, very smooth.

I do not understand how rewiring the starter could have caused any of this except the easy starting. The starter isn't even in use after the scoot has been started so how did replacing the starter wires help with the lights and low end or am I just experiencing some more coincidental luck?