linhai 260 charging problem

[hagedorn45]

I have a problem with the ground wire coming off the rectifier man it get real hot to the point if i leave in running i would burn the wire. One thing i noticed was the small ground wires are all connected to a large ground that follows the whole harness and can not find where it is connected to the frame except for one small wire that is hooked up to the back of the rectifier between the frame and rectifier is that normal or should that large ground wire be hooked up to the frame thanks

[bnc]

Most bikes have the main ground wire connected to the starter. The reason is that the starter draws more current than the whole bike combined with it is cranking.

[hagedorn45]

Thanks for your response if i could follow up on my last question. The reason i am working on the electrical part of this scooter (jcl with linhai 257 engine) is I melted the plastic connectors from the stator some have said it was do to me using a fiat auto to jump start the scooter. So i cut the plastic connectors out and spliced the wires with tubular connectors. That seemed to be ok when i tested the charging of the battery i was getting between 13 to 13.50 volts. But when i started it up the ground wire from the rectifier got so hot that running more would have melted the wire. So advise told me to try a new rectifier but that did not work. Then got more advice to install larger gage ground from rectifier directly to battery but did not work. Infact that made the yellow wires from the stator get warm. Then noticed that the main ground was not hooked to anything other then a small gage wire coming of the main was the only thing grounded. The thing that concernes me is that before the melting of the stator wires everything worked great and actually everything works now accept the wires getting hot. Sorry to be so long winded but boy is this frustraing

[bnc]

The main bike ground normally comes off the negative battery terminal and grounds the chassis at the starter. There are secondary grounds like the one you describe at the rectifier to stop ground loops that form because the steel frame is not that good a conductor. Without the secondary grounds, the starter ground might be at zero volts but the rectifier ground might be at +1 volts or -0.5 volts, etc.

Hooking to a car is not a problem unless you start the car. The scooter and car regulating systems do not work the same. For example, if the car system puts out +13.5 volts and the scooter normally does +13.0 volts, the regulator system on the scooter will try to absorb the extra voltage by attempting to load down the car. The problem is the car system can put out so much more power that the rectifier system on the scooter can fry before it can absorb the extra power.