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@vintage_red_matthew avatar
UTC

MV Santa
GTS250, 1975 VBC, 1980 P200E cutdown
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UTC quote
I was riding my GTS a couple days ago when the engine died and all the lights went out. I thought "what now?".

I coasted to a stop and it restarted but only for a few seconds and went dead again but by then smoke was coming out of the engine area and the throttle would not turn.

I took out the pet carrier and the throttle cable was melting. There was a massive short somewhere.

I thought I might be saying goodbye to my old friend.

I had to do something fast but I didn't have any tools.

The cable was too hot to touch with bare hands but I had gloves on so I was able to rip it out and the situation stabilized for the moment.

I went into the nearest store and bought a screwdriver and unhooked the battery.

When I got it home and did a quick inspection I saw a few melted wires. The ground wire that attaches near the data port under the seat had melted through.

I don't know the cause or extent of the damage but I can see areas in the wire harness that were obviously hot.

The next step is to expose the harness by removing the cover and go from there.

In the mean time Scooterwest shows the throttle cable is out of stock but I have a feeling that might be the least of my problems.

I know I don't have much information yet but does anyone have have any ideas of what might have happened?

Wish me luck.
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Gigi, '13 GTS 300ie Touring
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UTC quote
Sheesh, that sounds awful. I hope the issue isn't as bad as you fear and she is up and running soon.
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UTC quote
That's a scary moment for sure. I once grounded a hot wire (on an alarm system) working on a friend's jeep, and melted a good deal of the wiring harness. It was a bitch to fix.

On a scooter, assuming the ECU isn't fried, this is probably not fatal. At the very worst, you'd have to replace the whole wiring harness. That would suck, to be sure, but it would not be the end.

Hopefully, you won't have to go that far. But once wires in a harness start getting hot, they tend to melt through the insulation and make contact with other wires, which of course means that segment of the harness has to be replaced. I think you're going to have to do some investigation to figure out what's been damaged.

As to the cause, your first instinct was right: you've got a grounded hot wire somewhere. Probably unfused, so start at the battery and work your way back from there.
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UTC

MV Santa
GTS250, 1975 VBC, 1980 P200E cutdown
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UTC quote
It definitely could have been worse.

I am encouraged that it restarted after it first showed symptoms so I think the ECU is probably OK.

I'm going to have to remove the glovebox, floorboard and open the headset to replace the throttle cable so if I do have to replace all or part of the harness I can do that at the same time.

Meanwhile I have a GT as well and the water pump on that went belly up the day before so I am currently scootless.

At least on the GT I know what I have to do and it should be back on the road in a week or so.

It hasn't been a good week for scooters for me.
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UTC quote
vintage red matthew wrote:
Meanwhile I have a GT as well and the water pump on that went belly up the day before so I am currently scootless.

At least on the GT I know what I have to do and it should be back on the road in a week or so.

It hasn't been a good week for scooters for me.
Ooof. Sorry to hear that. Hope you make some progress on either.
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UTC

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1991 Vespa T5 Pole Position, 2008 Vespa S 125, 2023 Piaggio MP3 300HPE Sport
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UTC quote
vintage red matthew wrote:
It definitely could have been worse.

I am encouraged that it restarted after it first showed symptoms so I think the ECU is probably OK.

I'm going to have to remove the glovebox, floorboard and open the headset to replace the throttle cable so if I do have to replace all or part of the harness I can do that at the same time.

Meanwhile I have a GT as well and the water pump on that went belly up the day before so I am currently scootless.

At least on the GT I know what I have to do and it should be back on the road in a week or so.

It hasn't been a good week for scooters for me.
I hope that old saying about bad luck coming in three's isn't right in your case!
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UTC

Molto Verboso
Dongfang 170cc, CF Moto Fashion 250
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Molto Verboso
@kz1000st avatar
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UTC quote
This isn't anything new on a 250, is it? There is a thread about the high tension line under the seat toasting somewhere.

The first time I had heard of it was in Steve Williams blog. His 250 did it and his friend Paul Ruby hard wired all the connectors under the seat for him. That was about ten years ago.
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UTC quote
kz1000ST wrote:
This isn't anything new on a 250, is it? There is a thread about the high tension line under the seat toasting somewhere.

The first time I had heard of it was in Steve Williams blog. His 250 did it and his friend Paul Ruby hard wired all the connectors under the seat for him. That was about ten years ago.
Yes, the OP's situation sounds similar to what happened to me 8 years ago. I posted on the MV forum what happened and someone immediately responded with what to look at. They told me to look for a connector that can melt and shorted out the engine's electrical system. And that's what it was. Rather than install a new section of the wiring harness my friend Paul removed the fused link and soldered everything together. It's been running like that for 25K miles without an issue.

Here's what the link looked like:
Shorted and burned fused link.
Shorted and burned fused link.
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UTC quote
VESPAsfw3 wrote:
Yes, the OP's situation sounds similar to what happened to me 8 years ago. I posted on the MV forum what happened and someone immediately responded with what to look at. They told me to look for a connector that can melt and shorted out the engine's electrical system. And that's what it was. Rather than install a new section of the wiring harness my friend Paul removed the fused link and soldered everything together. It's been running like that for 25K miles without an issue.
I had forgotten about that. Thanks much for the tip.
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Molto Verboso
Dongfang 170cc, CF Moto Fashion 250
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UTC quote
Just in case you didn't think your followers commit your blog to their memories Steve.
OP
@vintage_red_matthew avatar
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MV Santa
GTS250, 1975 VBC, 1980 P200E cutdown
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MV Santa
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UTC quote
VESPAsfw3 wrote:
Yes, the OP's situation sounds similar to what happened to me 8 years ago. I posted on the MV forum what happened and someone immediately responded with what to look at. They told me to look for a connector that can melt and shorted out the engine's electrical system. And that's what it was. Rather than install a new section of the wiring harness my friend Paul removed the fused link and soldered everything together. It's been running like that for 25K miles without an issue.

Here's what the link looked like:
I had similar issues with those wires and the connector so I removed the connector, soldered the wires together and covered the new soldered connections with heat shrink tubing. You can bet that was the first place I looked and those solder connections are fine. That was not the reason this time.

It will probably take me a while to determine what happened. I might never know for sure what originated the incident but I will tell you all if/when I find out.

Before I tear into that, though I am going to concentrate on getting the GT back on the road so I have something to ride. As I said the fix for that one is straight forward.
OP
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MV Santa
GTS250, 1975 VBC, 1980 P200E cutdown
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UTC quote
While I'm waiting for the new water pump for the GT I started investigating.

As you can see it looks like I'm in for at least a partial wiring harness replacement.

I can't go much further until I remove the floorboard and glovebox.

I'm still wondering if will be able to know what caused it. Sometimes it is difficult to tell if a melted wire was the cause or was a result.

In the Apollo 1 fire, which was at least 10,000 worse than this they had an unlimited budget but they never able to determined the primary cause.

Stay tuned.
Forum member supplied image with no explanatory text
UTC

Hooked
Genuine Buddy 125, Piaggio BV 250
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WTF is that? Looks like a Lovecraftian nightmare!
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UTC quote
Ugly.
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2006 250ie
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UTC quote
Can we see a zoomed out shot too? I want more of a look at the lower left of your pic.
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MV Santa
GTS250, 1975 VBC, 1980 P200E cutdown
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UTC quote
phaskins wrote:
Can we see a zoomed out shot too? I want more of a look at the lower left of your pic.
I'll get a picture tomorrow.

The wire with no insulation left is a ground wire that attaches to the body on the left side just under the seat. The wire melted completely through two inches from the end.

Scooterwest has the complete harness for $580.

Ouch.

I may be fooling myself but I'm hoping I can repair the harness.

I once bought a Porsche 914 that had an engine fire that was much worse than this. I got it for scrap price and I fixed it and drove it for years after.

I guess we'll see.

Once I get the floor off I will know more.
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UTC

Sergeant at Arms
Weird 80's Vespas & Cool Vintage Lambrettas
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UTC quote
wow. wow. i've seen some carnage but nothing like that.

if i had to guess you've got a dead short to that cable. but to have your ground wire smoked that bad makes me think that you're dead shorted to the frame.

pull it all down and report, i'd be interested to know.

also, triple check ALL your grounds before proceeding. this is fixable but it's gonna take a little bit of finesse.

good luck!
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UTC quote
vintage red matthew wrote:
I'll get a picture tomorrow.

The wire with no insulation left is a ground wire that attaches to the body on the left side just under the seat. The wire melted completely through two inches from the end.

Scooterwest has the complete harness for $580.

Ouch.



I once bought a Porsche 914 that had an engine fire that was much worse than this. I got it for scrap price and I fixed it and drove it for years after.

I guess we'll see.

You certainly did. Just in case everyone is wondering that was my first Vespa that mysteriously caught on fire. A phenomenon never fully explained.
OP
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MV Santa
GTS250, 1975 VBC, 1980 P200E cutdown
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UTC quote
I know what you are thinking. "That's a hopeless mess."

It's a mess to be sure but if it doesn't get a lot worse than this I think I can fix it. At least I'm going to try.

I'm going to exteriorate the posterior half of the harness and replace or cover in shrink tubing every damaged wire.

The conductors on all but one of the wires are intact and the one that is broken is obvious. It's the one wire without any insulation left and grounds next to the yellow relay.

Worst case: I will replace the entire harness.
Forum member supplied image with no explanatory text
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UTC quote
vintage red matthew wrote:
It's a mess to be sure but if it doesn't get a lot worse than this I think I can fix it. At least I'm going to try.

I'm going to exteriorate the posterior half of the harness and replace or cover in shrink tubing every damaged wire.
I approve of this plan. Not that you need my approval. But just offering it anyway.
vintage red matthew wrote:
Worst case: I will replace the entire harness.
That option will always be there, so you've got little to lose by attempting the repair of the existing harness.
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UTC

Veni, Vidi, Posti
GT 200
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UTC quote
What battery is in the bike?

We've been selling more of the wiring harnesses this year than we have in a few, more than likely because a lot of people are buying ones that have been sitting for a while and sticking whatever battery fits in it. Then the harness melts. It could be worse, Piaggio has discontinued the harness for the 250 GTV.
As far as the throttle cable, I think the one on the GTs comes with the throttle assembly too. That's what we've got here now, and I can't remember seeing the cable offered alone.
Good luck patching it back together and hoping for the best. I've seen that tried before, usually with theft bikes.
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UTC quote
I pulled most of the rear half of the harness out and opened up the loom so I could inspect the wires.

I think I may have found out what happened but as I said before it can be hard to distinguish what caused it from what was a result.

There is an area in the loom below where your right foot is when you are riding where about a dozen black wires of different sizes come together from the front, back and the negative terminal of the battery and join together.

The wires are stripped, twisted together in a pointed cone shape about the size of a thimble then they are soldered and then folded over. There is no insulation on the twisted cone.

It would appear that over years of heat, cold and vibration the solder joint gradually lost its integrity and developed resistance causing it to heat up and the point of the cone melted through to the wire leading to the positive terminal of the battery.

No bueno.

You can see in the pictures one wire in particular that has all the insulation melted off. That is the main ground wire for the body and the melted insulation goes up to where that soldered joint is and no farther.

At some point in that ground wire it must have been in contact with the throttle cable, melted through that causing it to ground out the short too.

I haven't opened up the the headset yet but from what I can see those wires are not damaged. The throttle cable going into the headset is melted so I'm hoping that's all the damage there.

You might think that all the wires in the loom are orderly and in line but they are not. Many of the wires are too long and the excess is just bundled up and covered.

I've been interrupted. More coming.
⚠️ Last edited by vintage red matthew on UTC; edited 1 time
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MV Santa
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Continued:

The ground wire that shorted out near the battery grounds to the body more than two feet away. There is no reason it can't ground near the battery. That would have prevented this.

Also the yellow charging wires that go from the stator to the voltage regulator are much longer than they need to be. I may shorten those too.

In case you didn't notice I'm not impressed with the quality of the wiring harness.

I think there's about a 75% chance that I can repair and save the harness. It will be tedious but straight forward.

It looks like you have to remove the fuel tank to replace the wires going to the rear turn signals, brake and tail lights. I'm not doing that. If I do replace the harness I will cut and splice those wires into the new harness.

I am going to take a break from it while I order parts and work on other projects. I got the GT running so I have that to ride.

I will keep you posted.
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UTC quote
I was going to say I wouldn't start the wiring harness change until you have a reasonably good idea of what caused the problem. I usually forge ahead only to have the problem repeat itself.

That would be terrible after all that work.

But since you have a good idea of what caused the mayhem -- full speed ahead.

Looking forward to seeing how things go.
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UTC quote
This thread is my very favorite kind of content on MV. Yeah, it sucks for vrM, but watching this problem unfold and the solution evolve is priceless.

Props to you!
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UTC quote
jess wrote:
This thread is my very favorite kind of content on MV. Yeah, it sucks for vrM, but watching this problem unfold and the solution evolve is priceless.

Props to you!
I've learned a lot from the mechanical trials and tribulations of others here. I'm grateful to witness the solutions from the comfort of my easy chair.

There's something seductive about seeing something puzzled out. It may be why I've suddenly become an addictive viewer of Matt's Off-Road Recovery videos on YouTube. It's fun to watch them solve things in places I'll never get to ride into. And it's always satisfying for me to watch people who have great competency in some area of human endeavor.

Here's an interesting one rescuing a KTM motorcycle rider:

OP
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GTS250, 1975 VBC, 1980 P200E cutdown
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UTC quote
One more picture.

You can see the twisted cone.

It got hot and the point punctured the insulation of the positive battery cable. (that's the theory)

To the left of the cone is the ground wire with the insulation melted off. I haven't seen any wires forward of that that were damaged, however the throttle cable is melted along it's entire length and I haven't opened the headset to check there but I'm hoping there is no wiring damage there.

It will probably be a while until I update further. I need to order a throttle cable and literally 100 ft of heat shrink tubing.

Also I have decided that if/when I get it running I am going to replace all of the coolant hoses. It's 14 years old and past due.
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UTC quote
Cool to see you making progress on this. Hope it comes together.
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Veni, Vidi, Posti
In garage: Yamaha Tricity 155 Urban 2019 - MV Agusta 125 RS 1956
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UTC quote
The wrong thing about the wires that come together in the "twisted cone" is the soldering to join them. At that point there was a terminal block just to avoid situations like that. Then separate the wires and join them with a terminal block that you will insulate with heat shrink tubing.
@max6200 avatar
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UTC quote
jess wrote:
Cool to see you making progress on this. Hope it comes together.
What could go wrong?***eyelashes****
@steelbytes avatar
UTC

Veni, Vidi, Posti
2019 GTS 300 HPE Supertech E3 63,000km
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@steelbytes avatar
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UTC quote
VESPAsfw3 wrote:
There's something seductive about seeing something puzzled out. It may be why I've suddenly become an addictive viewer of Matt's Off-Road Recovery videos on YouTube. It's fun to watch them solve things in places I'll never get to ride into. And it's always satisfying for me to watch people who have great competency in some area of human endeavor.

Damn you, watching that is so addictive 😀
OP
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MV Santa
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UTC quote
steelbytes wrote:
Damn you, watching that is so addictive 😀
Sounds good. I'll have to check that out.
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