I purchased a Merida 550 off EBAY. I got it dirt cheap. Part of that reason was because it did not have a battery pack with it. I had a vendor tell me he could acquire a Merida Battery pack for me but after winning the auction and placing the order with him he later informed me he couldn't get them anymore. So I decided to build my own. I purchased a wiring harness and battery charger from Electric Rider and bought 2 - 12 Volt 18 AH AGM batteries locally. My intent was to wire them in series and of course I had discussed this with the guy at Electric Rider. He said their harness was for 36 volt systems but that it would work fine for a 24 volt system I just wouldn't need the second jumper wire for the batteries. His jumper wire contained a fuse in it to protect the batteries. Or at least I think thats why it was there. And even though I didn't necessarily need an ignition key switch it was included in the harness. So last night with all the parts having arrived I assembled everything. I wanted the installation to look professional so I took the time to carefully remove a bunch of the side guards and plates that hid all the wiring, motor, controllers etc. I found the wires that went to the battery lugs and simply slipped my wire ends under the screws and retightened them. Of course I put an end connector on the wire first that had a round washer type end that fit over the hole that the screw went through. After getting everything wired up correctly and all my guards and everything put back in place I switched on the key. There was a loud POP and upon investigating I discovered the 40 AMP fuse in the fuse holder that was wired into the jumper that connected the two batteries together in series was completely blown! So I doubled checked all my connections to be sure I hadn't wired up the wrong polarity. All was well. However, I did disover one connection where the two blade connecters joined the connectors themselves were touching the bike frame. It was on a negative wire which I thought wouldn't be important but maybe it is. Obviously I can easily put some electrical tape around that connection or heat shrink some insulation around it but I am wondering if that really is the problem. I may try it as soon as I can go out and buy some more fuses. I only had the one. And of course I know I can call Electric Rider for advice come Monday but of course I'm impatient and wanted to be up and riding this bike over the weekend. So I thought I would ask here if anyone has any advice on how I might track down my electrical problem. If I do insulate the one spot where the wire was touching the frame and it still blows the fuse how should I go about checking for the problem?
Thanks so much in advance for any helpful advice anyone might offer.
P.S. I went ahead and drew up a diagram showing how I wired it. I'll attach this to my post.