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post #1 of 10 (permalink) Old 04-21-2012, 11:12 AM Thread Starter
 
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Exclamation Almost lost my revolt to an electrical fire

Check your wiring at the inverter. Oil has seeped through the wiring from the stator and made the wiring brittle and caused it to crack. The wiring shorted on something and started to burn. Luckily I caught it after about 10 seconds and manged to get it out. An electrician friend tested my inverter with his equipment and it has survived but we have to replace a bunch of the scorched wiring. Hopefully we can get it sorted out and go riding later. Everything always seems to break on my revolt just before a group ride

Edit: Got the wiring harness all fixed up (used about 2' of new wiring in total) and cleaned up as much of the oil out of the stator connections as possible. Had to solder new wiring onto the inverter as the wire burnt up to about 3/8" from the box, and then put some electrical epoxy over the solder to reseal it. Went over the whole wiring harness and inspected it but found no other damage. I read on an old thread about this happening to others so I guess its something i'll have to remember to keep an eye on.

Spent most of the day at the local dunes with no problems. I still can't get over the attention the revolt gets. I always have curious folks coming over to check it out when my group stops for a break.

Last edited by KaneNorth; 04-21-2012 at 06:41 PM. Reason: End of ride update
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post #2 of 10 (permalink) Old 04-22-2012, 06:06 AM
 
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Re: Almost lost my revolt to an electrical fire

I suspect we all have that issue. I have it on mine. Does anyone have any idea why this is happening or how to cure it?



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post #3 of 10 (permalink) Old 04-22-2012, 09:48 AM
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Re: Almost lost my revolt to an electrical fire

It's siphoning oil through the stator wire essentially. No cure I've heard of, but it's been a topic a few times. Making checking the wiring for cracks look to be another maintenance procedure...
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post #4 of 10 (permalink) Old 04-22-2012, 10:01 AM
 
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Re: Almost lost my revolt to an electrical fire

Mine's also is doing that same thing... Cleaned all my connectors yesterday, and that one was full of oil..... Is the oil coming through the wires themselves... I didn't think that there was any space between the twisted wire and the Plastic shielding for that to happen. Not sure how you can resolve this!


Is the oil in the connector really a big problem for now? the oil doesn't seem to affect the electrical system at all...I guess if there is no fix, then we just need to keep checking our wires for Brittleness I guess?
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post #5 of 10 (permalink) Old 04-22-2012, 12:57 PM
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Re: Almost lost my revolt to an electrical fire

Could it be crankcase pressure? I found my crankcase breather hose was kinked.
I also have oil in the stator connector.
It could also be the capillary action of the oil, drawing it up the space between the cable strands.

KaneNorth, your solder should stop the oil. The solder will wick between the strands of copper.
Maybe thats the fix? Cut back the insulation, clean and solder the cable strands, making a solder dam, to hold the oil back. Then re-insluate the cables like you did.

I'm glad your car didn't burn. That would suck.



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post #6 of 10 (permalink) Old 04-22-2012, 01:25 PM Thread Starter
 
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Re: Almost lost my revolt to an electrical fire

Quote:
Originally Posted by Bear Foot View Post
I'm glad your car didn't burn. That would suck.
I store my revolt in one of those plastic garage tent things and had just started it up to warm it up while i hooked up my trailer. I turned around for a second and the whole tent was full of smoke. Ran over there and shut it off and flailed my hand around in there by the inverter to smother the flames (had heavy gloves on).
I think I will start carrying a small fire extinguisher on my revolt now. It would really suck if it got out of hand as my dad stores his ranger 6x6, quad, and snowmobile in the same tent.
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post #7 of 10 (permalink) Old 04-22-2012, 01:59 PM
 
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Re: Almost lost my revolt to an electrical fire

Here's what I've found. The stock crankcase breather line is only 1/8" diameter inside. The crankcase breather outlet (at the motor) is 1/4". Where the breather line hooks to the oil tank is 3/8" (I think). I didn't realize the stock breather line necked down to only 1/8" inside diameter until I cut it in half to do some changes. That line isn't enough to allow the pressure to escape and then it has to go somewhere else. My line is now 3/8" off the motor up to the tank and I no longer see the oil leaking from my stator wires.

Also, the stock routing for the breather line goes under the motor creating a "p" trap of sorts, so if you get oil in the line, venting will be restricted. Run your breather line up and over the motor to prevent that (thanks to Pilot for that idea!)

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post #8 of 10 (permalink) Old 04-22-2012, 05:26 PM
 
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Re: Almost lost my revolt to an electrical fire

Thanks Eric. I Will correct mine that way. How did you increase the 1/8" port at the motor? Nevermind. I reread your post. Easy fix. Great info.



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post #9 of 10 (permalink) Old 04-22-2012, 06:31 PM
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Re: Almost lost my revolt to an electrical fire

Good call Easy E and Pilot. Thats a cheap easy fix.



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post #10 of 10 (permalink) Old 04-22-2012, 07:42 PM
 
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Re: Almost lost my revolt to an electrical fire

Quote:
Originally Posted by Easy E View Post
Here's what I've found. The stock crankcase breather line is only 1/8" diameter inside. The crankcase breather outlet (at the motor) is 1/4". Where the breather line hooks to the oil tank is 3/8" (I think). I didn't realize the stock breather line necked down to only 1/8" inside diameter until I cut it in half to do some changes. That line isn't enough to allow the pressure to escape and then it has to go somewhere else. My line is now 3/8" off the motor up to the tank and I no longer see the oil leaking from my stator wires.

Also, the stock routing for the breather line goes under the motor creating a "p" trap of sorts, so if you get oil in the line, venting will be restricted. Run your breather line up and over the motor to prevent that (thanks to Pilot for that idea!)
Eric is right about the fix for the problem. The connection at the oil tank is 3/8". You can also cut or slice the wire insulation close to the connector to allow the oil that does make it that far to drip out before it reaches the plug. It makes a mess that needs to be cleaned after a weekend of riding but its not that bad. I just put a velcro patch over the sliced area to protect from shorting. Thanks for the great ride yesterday at Florence with Eric and Jim. Scott, Larry and I went out today for a great last ride before having to come home. Didn't break any frames or belts today at all!
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