Burning wires.

[Gokartjoe]

Had a question about the wiring on a go-kart. When I hook up the positive cable on the battery my wires start to burn up. I have a three phase regulator rectifier is that causing the problem of the wires getting burned up should I replace it or is it the CDI. Thanks any help will be appreciated.

 

[mckutzy]

Hello and welcome..

What's the kart/motor???

Pics??

 

[Gokartjoe]

it's a cn250 motor .. don't know the exact brand of the go-kart but if anyone knows I would help too. Thanks

 

[Gokartjoe]

Anyone?

 

[Texan]

Don't know anything about the kart or engine, but sounds like something is shorting out. Does your kart not have a fuse? Follow the burned wires. Do you have an multimeter?

 

[Whitetrashrocker]

Electrical is extremely hard to diagnose online through pictures.

Your gonna need a meter and start probing. Something sounds likes it's grounding out.
I'd start at the battery and follow every wire till you find damaged wire harness or a faulty part like a relay or switch.

 

[Gokartjoe]

Thanks for the info

 

[anderkart]

Tell us the symptoms of how this problem first started, that might give us some good clues...

What wires are burning? - Some of the smaller wires, or do you mean the larger battery cables?
___________

If the battery cables are burning, the first culprit I would suspect is:

The starter is shorted, and this damaged the starter relay by melting/fusing its internal contacts together, so its now constantly sending power to the defective starter.

Try disconnecting the cable from the starter and see if the short goes away.

 

[Gokartjoe]

I'll have to post a picture .

 

[itsid]

most vertaily a short circuit..
where cannot be guessed by what little info you gave us.

BUT..there's a more or less easy way to tell:

the burned wire!

No really.. the hottest spot (where it burned first)
ist almost exactly half way between the positive and negative poles it gets fed by..

So if your burned spot is a foot from the battery terminal (in case we talk uniform wire gauge)
it'll be a foot from the culprit part/connection.

only exception worn insulation-short.. they burn on sight

'sid

PS most likely there's a misconnection on some part.. something grounded that mustn't be,
CDI installed incorrectly or a wrong one etc...

 

[landuse]

No really.. the hottest spot (where it burned first)
ist almost exactly half way between the positive and negative poles it gets fed by..

I didn't know this. Thanks!

 

[itsid]

I didn't know this. Thanks!

since it's an overstatement really

But on very simple and straight forward wiring harnesses
(like I would want to assume on a kart like that)
it might be just good enough to get an idea where to search for the culprit

Oh just in case someone misunderstood..
if you have a burned wire (by accident) it can give you a clue..
DO NOT knowingly reproduce such short to get such burned wire
Everytime you repeat the mishap, the next weakest link in line will likely go/blow and you need to repair/replace another something.

'sid

 

[Karttekk]

Like Sid mentioned, check the CDI module. Most karts use an AC type, American Landmaster or Manco use a DC CDI. If the wrong CDI is installed it will blow a fuse or the CDI immediately. Disconnect any ignition components and any lighting to eliminate any shorts. Connect the battery cables then connect one component at a time while watching for any wires starting to heat up. The culprit should show up this way. Check the key switch also for melted wires and make sure the starter or relay isn't shorted. Process of elimination.

Thanks