700Li wiring melt-down

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benmart
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Last seen: 10 years 10 months ago
Joined: Tuesday, August 12, 2008 - 18:53
Points: 71
700Li wiring melt-down

I'm sorry to report that I had several wires on my 700Li short and cause the rear tail-lights to go out. The wires are the yellow and green coming our of the controller at the point where they are connected with metal connectors to go outward to the tailights.

They melted the the plastic bag and thank goodness no other damaged was caused. All other electrical system still work. Needless to say, this has stopped any night-time driving.

I called X-treme and got a ticket number and since it's only been two days it's too early to report how this was resolved. Has anyone else had this problem?

solutionsgem
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Joined: Tuesday, July 29, 2008 - 17:00
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Re: 700Li wiring melt-down

Hi Ben, I am worried that might be defect with all the bikes. I am going to check my wires for loose connections. Do you use your bike for long periods of time with the lights on?
The lighting system carries 48 volts. I wonder if that makes the wires hot. Perhaps the connection was loose. That is one of the reasons I do not like incandescent lighting. Most of of the energy is wasted in heat generation. High power LED do also get hot but not nearly as much.

Xtreme seems to responsive enough with issues. I just got instructions on how charge the bike through the seat post. I know they are kind of late. But I know at least they are trying.

I am currently experimenting with 12 volt LED lighting. I am undecided whether to install a DC to DC converter to replace all the lights or to only connect resistors in series to the headlights to convert the 48 to 12 volts. You can view my results here:

http://visforvoltage.org/forum/4776-xtreme-700li-led-lighting-project

Good luck to you.

Al

Energy Independence For A Bright Future.

www.solutionsgem.com

benmart
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Last seen: 10 years 10 months ago
Joined: Tuesday, August 12, 2008 - 18:53
Points: 71
Re: 700Li wiring melt-down

Al, I was riding my bike at night and day-times with the lights on (safety during day-time). I contacted X-treme about the electrical problem and here is:

the reply

Please check the wires in your battery and controller area. Give each wire at the connection a firm but gentle tug pulling away from the connection. Look for any loose, bare, blackened, broken, or disconnected wires.

1. Check the wires at the rear of the charging socket.
2. Check the wires at the rear of the fuse holder.
3. Check all fuses.
4. Check the wires that connect the batteries together.
5. Check the connections on the controller.

We know this is a lot to ask but we do appreciate you helping us to better help you. Please reply with results.

Thank You,
Edwin

Here is my reply

Edwin, I did as you asked. I have to correct my orginal ticket. The wires in question were the yellow and green and they are not melted.

What was melted is the clear plastic connectors that joint the male/female ends of the wiring together. I removed the melted residue and checked the wires which are intact. I checked everything else you suggested and all appears okay.

What I did discover is that the rear tail-lights are both burnt out and so is the license plate light. The brake light, which shares the same bulb as the tail-light, still works. One of the filiments on each tail-light bulbs is burnt so that explains the "no-tail-light" problem.

Turn signals work, brakes lights work and head-lights work. So, if you could send two new tail-light bulbs and license plate bulb I can install and see if the same thing happens. Thanks again.

And the Tech's reply

Benjamin, I have ordered tail lights for you I do not have the licence plate bulb I got some on order as soon as they get here I will let you know. If you have any more questions please reply here.

Thank You,
Edwin

Al,I rode my scooter the other day for eight blocks during day-time with no lights on and the wires are hot to the touch, so hot, I couldn't touch the connectors very long. I wish they would have made the electrical system 12 volts for US and Canadian orders. It's a pain having to order something as simple as light bulbs !

All-in-all, I still like it and will work with X-treme to get the problem resolved. I am heading over to your post to check out the LED project.

Ben - Modesto

benmart
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Last seen: 10 years 10 months ago
Joined: Tuesday, August 12, 2008 - 18:53
Points: 71
Re: 700Li wiring melt-down

Xtreme sent me a new controller and tail-lights. No more overheated wires or hot controller. All seems to be working as it should in fact I think the bike is going a bit faster than before[/quote]

Ben - Modesto

ttunes
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Last seen: 9 years 10 months ago
Joined: Monday, August 25, 2008 - 12:21
Points: 72
Re: 700Li wiring melt-down

Hey Ben - glad to hear things are better on your scoot.
I'm looking at the schmetatic -- mind you I am no pro on these things....
It would seem to me that you had high currents melt your wires....so how can that happen when a new controller seems to give you a little more pep? I'm wondering if the +V connections that share the lights with the controller were the root of your issue?? Just a guess. don't know -- we'll probably never know.

Anyway --- good to hear you have a positive story ending.

Thom

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