Troubleshooting Guide > Motor to Controller Wire Insulation or Connectors Have Melted
Motor to Controller Wire Insulation or Connectors Have Melted
If the motor to controller wire insulation or wire connectors have melted this is caused by overloading the motor or controller beyond the capacity which they were designed for. This can happen on stock electric scooters, bikes, go-karts, and other similar vehicles if the vehicle is driven up an incline that is too steep for the vehicle or if the vehicle is overloaded in another way such as going through deep sand or mud. When this happens to a modified or custom-built vehicle the problem is most likely that the gear ratio between the motor and wheel or axle is too high for the conditions that the vehicle is being used under. A motor which has been overloaded causing it to have overheated coil winding can also cause this type of problem to happen. The root cause of what is making the wire insulation or connectors overheat and melt needs to be addressed and corrected before replacing the damaged parts otherwise the same problem is likely to happen again.
Determine How the Motor or Controller Was Overloaded for an Unmodified Vehicle
When the motor to controller wire insulation or wire connectors have melted on an unmodified "stock" electric scooter, bike, go-kart, and other similar vehicle determine what the riding conditions are to narrow down which riding condition caused the overload. Any riding condition which slows down the vehicle such as riding up inclines that are too steep for the vehicle or riding through tall grass, sand, or mud may be the cause of the problem. Towing and drivers that are over the vehicle's driver weight limit can also be a cause of the problem.
Determine How the Motor or Controller Was Overloaded for a Modified or Custom Built Vehicle
When the motor to controller wire insulation or wire connectors have melted on a modified or custom-built vehicle the vehicle will either need to be driven under easier conditions or the gear ratio between the motor and wheel will need to be changed to give the vehicle a lower gear ratio. For more information on selecting the proper gear ratio for a modified or custom-built vehicle we have a Drivetrain Parts Selection Guide page.
Here are some other links that may be helpful with lowering the gear ratio:
Bolt Circle Diameter Calculator: https://electricscooterparts.
Chain Length Calculator: https://electricscooterparts.
Custom-Made Sprockets Page: https://electricscooterparts.