Discovered source of my starter issue

[TroutBum]

For the last two months the starter on my Like has been acting up. It generally started first ride, but if I shut down the engine for say fueling it would not restart. When I hit the starter button the starter seliniod would click. In order to start the engine I discover if I held the starter button while I jumped up and down on the scooter it would start. Some suggested checking and cleaning the various starter connection. I did that and found it seemed to help for a few days before the problem returned.

Today I was out riding and at the end of my ride I fueled up. Within a mile my scooter began to cut out and then died altogether. I pulled over to the side of the road and tried starting it again. The starter turned, but the engine would not start. Waited a minute and it started right up. At that point I headed home thinking maybe the spark plug cap had come loose. My ride this morning was on a fairly rough rode so I figured that could have loosen the spark plug connection.

When I got home I pulled the seat/pan and inspected the spark plug connection. It was fine. I then went through my starter connections and that's when I noticed the grounding cable was just laying on top of the engine casing. The bolt had worked it way loose and is somewhere on the side of the road. The grounding connection is approximately 3/4"" long. Because of that it made just enough of a contact for the scooter to sporadically start given the impression that either the stater motor or relay was on its way out. Today's ride on rough terrain moved the grounding cable where it finally lost contact with the engine casing causing the stall. I can see some black streaks on the casing where the loose ground cable had arced.

The parts diagram isn't always the easiest to determine parts. Can some one confirm the grounding cable bolt size for me? It's located on the righ crankcase cover above the fan housing. The bolt I got from my local hardware store is a 6x35 metric flang bolt. I think from the parts diagram it should be a 6x28 metric flang bolt from what I could figure out from some of the Kymco online parts supplier diagrams. From my Cyclepedia Kymco 200i Manual The bolt in question can be seen in the engine removal and install section. In that section they talk about removing/returning the bolt for the grounding cable. That is for those who have a Cyclepedia subscription. Cyclepedia only gives the socket size and nothing more about the bolt, but at least you can see the bolt in question.

If you are experiencing sporadic issues with your starter and the connections are fine add the grounding cable to your list of items to check.

[DMblues01]

I had that exact same problem with a truck I used to have. I had some engine work done at a shop, and they forgot to bolt the ground wire when they put it back together. They just had it laying on top of the engine. I discovered it after I already changed out the starter, and felt like a moron for not thinking of that first.
It's a ridiculously simple issue that just gets overlooked sometimes. It's the easy solutions we usually forget to check.

Live and learn! 

[TroutBum]

I had that exact same problem with a truck I used to have. I had some engine work done at a shop, and they forgot to bolt the ground wire when they put it back together. They just had it laying on top of the engine. I discovered it after I already changed out the starter, and felt like a moron for not thinking of that first.
It's a ridiculously simple issue that just gets overlooked sometimes. It's the easy solutions we usually forget to check.

Live and learn! 

True. When I first looked over the wirings a month or so back I completely ignored the grounding connection. You never think of the main electrical route be a source of the problem.

[Stig / Major Tom]

GREAT post. Thank you there, Trout
(I was thinking your electrical issues might be due to the coconuts in the passing palm trees, sunshine and the Pacific Ocean ..... Glad you found otherwise)
I studied the parts picture and the cyclepedia....
Maybe best to ring up Kymcopartsmonster help line - the fellow there has been very helpful to me in the past. Do NOT tell him you're calling from SantaMonica (or Barbara) - or he might just say"Tough Nooggies!" and hang up. I would.
Seriously, I'll be checking my wires tomorrow!
If you can give me a picture of it....I may have it in the 20lbs of hardware I purchased from a wrecked LIKE.
I'd send it to you for a coconut, or for free.
Stig

[TroutBum]

Sorry Stig, but the only coconuts here are sold in the produce section.

I don't have a picture of the bolt, all that I could find was a shot (pi) of the head of the bolt. I'll give the kymcopartsmonster helpline a call.

Below is a picture from Cyclepedia showing the bolt (head).

[Stig / Major Tom]

Sorry Stig, but the only coconuts here are sold in the produce section.

I don't have a picture of the bolt, all that I could find was a shot (pi) of the head of the bolt. I'll give the kymcopartsmonster helpline a call.

Below is a picture from Cyclepedia showing the bolt (head).

What the heck ? No coconuts - what kinda tropical paradise are you guys running out there?!
If somebody asked me for a cow, I could send them one....helsbells we even have a Llama farm nearby - or are they Alpacas? He's trying to mate them with a cow, or a deer...
Anyway, I removed my little hex bolt as seen in your pix...it is the same as the one I took out yesterday to free the rear brake line from it's little support. See my recent DIY post for rear brake RR.
Seems like there are a bunch of these on our scoots - just different lengths. Most are shorter - some long - like holding the belt cover on. 8mm heads.
I have some spares so if you want to PM me with your address, I'll get one in the mail to you tomorrow (I'll pick up the coconut next time I'm on my way to Haight Ashbury)
If you want one sooner - I took a metric bolt from the LIKE to Lowes - they have sample places to screw it in, so you can find the proper threads, etc. Bought a little bag of stainless steel screws and washers to secure my little exhaust heat shield. Simply remove that little gold colored  8mm hex head bolt that holds the support for the rear brake line with you, get one like that or a touch longer.
Let me know....be glad to help a fellow scooterist...
(would send a photo of my screw - but we have been under a tornado warning twice tonight....one was sighted about 4 blocks away then it headed for my scooter grounds! Actually had the family, pillows, blankets and dog huddling in the small hallway. First time ever for that..... Apparently they never actually touched the ground.)
Stig

[TroutBum]

Thanks for the offer Stig. I sent you a PM.

Out west we have earthquake. They hit without warning. I can't imagine living under a tornado threat. The anticipation has to be stressful. Stay safe.