Post by 90GTVert on Feb 15, 2010 5:50:42 GMT -5
Upgrading Battery And Starter Cables
I was talking to a friend and kept looking at the size of the cable running from the starter solenoid to the starter motor. Pretty tiny, 10-12AWG crappy wire. I have a little bit of nice 2, 4, 8, & 10AWG power cable hanging over my workbench. Hmmm. 2 and 4AWG are way overkill, 8 is overkill, and 10 is not that much bigger. I decided on 8AWG. If this won't get the scoot crankin' I'm not sure what will.
Stock vs 8AWG
8AWG cable installed.
Top to bottom : My 8AWG cable, battery to solenoid, solenoid to starter, frame to engine ground, battery to frame ground.
The stock battery cable has two connections into one terminal. It makes things a little faster when connecting or disconnecting the battery, so I kept it that way. I stripped the smaller wire back enough to wrap it around the 8AWG wire and solder them together before crimping. If you use this method you may want to try a 6AWG ring terminal instead of 8AWG. It makes fitting the extra wire and solder much easier.
Both battery cables installed.
Battery to frame and frame to engine grounds mounted to their original location. Not all scooters directly connect the engine, battery, and frame cables at one point. I prefer to find a spot that works to connect them all though when upgrading cables.
The other end of the frame to engine ground used to mount to the case using a CVT cover bolt.
I moved it directly to the starter and used a slightly longer bolt to make up for the ring terminal and a washer.
I didn't really think it would make a difference, but it's actaully an obvious one. I'm getting close to cranking this 99cc over like a 50-70cc. Not quite, but it's getting to a point that I trust it more. It's amazing what cleaning the starter and putting a beefy cable on can do.
If you still don't have the cranking power you need, you may want to consider a few things. Check battery voltage and condition, because if it's not supplying the power that your starter requires, no cables can fix that. You may be able to gain cranking power by using a different battery. Check the cranking amp specs of your battery and compare to others. Replacing the starter with a new one, or perhaps a high-torque replacement starter. Checking compression. Sometimes compression is pushed too high with performance builds and the starter may struggle even if everything is in good condition.