Wiring issue

[Chickles]

I'm not sure I'm in the right spot for this but here goes..I have a daymak Gatto and the charger connection had a connector clip that got melted because someone tried to sauder the wires into it..so my bf hooked the wires direct and now it won't charge unless the key is in the ignition with the headlight on.the minute I shut the headlight off it stops charging.Could the ignition wire and the charging wire be mixed up?

 

[tomjasz]

Sounds like there's more to the story regarding the wiring. Something has been changed.

 

[Chickles]

Well yes...we bypassed the connector clip and hooked the wires direct.The light on the charger is green even though I know the batteries aren't charged.The batteries are brand new.I rode this bike flawlessly for 2 months but when the charging connection became frazzled my bf tried to sauder the wires back into the plastic clip and burnt the clip so upon the advice of other electric bike riders I know we wired them direct. That's all that was changed.

 

[tomjasz]

POST SOME PICTURES. What's a connector clip? It will make it easier to understand. Do you have a multimeter to test wires and voltages?
Did he solder the connector from the charger? What does frazzled mean? Trying to help others will too. But we need to have a better understanding of exactly what he did.

 

[Chickles]

Ok so frazzled means the wires were frayed.A connector clip is a white plastic peice as you can see in this pic that connects wires. When my bf tried to sauder the wires back into the connector clip he burned the clip and melted it and the wires wouldn't go back in.I tried to find a similar clip but could not and other ebike owners I know said to just bypass the clip and wire them direct. Maybe they are connected wrong.Where you see the black tape is where they are connected to the charging port.

 

[tomjasz]

It sounds like the wiring is wrong. Best to keep the BF away...

 

[Chickles]

I can post more later.. I have to go now

 

[indianajo]

This appears to be a scooter, not an electric bicycle.
If it was a bicycle, this goes on maintenance forum, not the general discussion forum.
The one thing that could be learned from all this is that the daymak gatto is garbage, so nobody else that can do research will ever buy one.
I built my electric system with dorman .157" bullet connectors, made in taiwan, that won't melt out at 35 amps. 5000 miles, 2 years, no electrical problems.

 

[Chickles]

It sounds like the wiring is wrong. Best to keep the BF away...

You may very well be right.

 

[Chickles]

All in all besides liking the look of the daymak Gatto I have found that was a complete pain in the ass to change the batteries..you have to take the bike apart ffs. Maybe I'll take it to a dealer and get it fixed properly.Looking online for anything regarding this scooter is horseshit.

 

[harryS]

It's OK to bypass the charge connector if it was damaged and connect to the wires that used to go to it. However, it should be possible to find a new connector,

It's not OK to rewire the charger direct to the cell outputs. Since your charger is now related to the light switch, something like this may have happened.

If you wire the charger to the cells directly, you may no longer have the overcharge protection that came with using the charger connection. Makes for a potential fire hazard if the charger goes bad.

 

[tomjasz]

This appears to be a scooter, not an electric bicycle.
If it was a bicycle, this goes on maintenance forum, not the general discussion forum.
The one thing that could be learned from all this is that the daymak gatto is garbage, so nobody else that can do research will ever buy one.
I built my electric system with dorman .157" bullet connectors, made in taiwan, that won't melt out at 35 amps. 5000 miles, 2 years, no electrical problems.

Jeez, I thought I was a curmudgeon! We both made mistakes every bit as agregeous.

 

[Chickles]

It's OK to bypass the charge connector if it was damaged and connect to the wires that used to go to it. However, it should be possible to find a new connector,

It's not OK to rewire the charger direct to the cell outputs. Since your charger is now related to the light switch, something like this may have happened.

If you wire the charger to the cells directly, you may no longer have the overcharge protection that came with using the charger connection. Makes for a potential fire hazard if the charger goes bad.

Thank you so much. What you said makes sense.Will be looking closer into it.