Grounding through powdercoat

[MRSOUND]

Last year I had the frame, handlebars and other various parts of my KLT160 powder coated. Since then the start/stop switch does not work nor do the lights. It also gives me the occasional jolt up at the switch housing. Tried a different switch housing with same results (no shut off and still getting jolts). Trike will start but gotta stall it or pull plug wire to shut off. Other than the switch on the handlebar the only other ground point I see is at the coil. Do I need to take the powder coat off where the coil bracket contacts the frame? What about on the handle bar? Why does it effect the lights? Electrical illiterate here so be nice.

[jonolanracin]

I always grind powder off where the ground connects . have you checked all your wires to make sure they are all intact and not bare anywhere .i have coated all my handle bars with no issue but im not sure if your 160 on off switch would ground to bars or not

[oscarmayer]

here is your issue. you have the engine mounts powder coated too. so in essence grinding the frame at 1 spot will not fix it. you would need to grind off the outer side of the engine mounts where the bolts press agaist the coating, then the inside where the engine makes contact (or spacers), and also the coil assembly connection to the frame. this would me the only way to resolve all grounding issues.but, you could try something easier. connect a grounding wire to behind the coil bolt (using a wire with a eye hole connection on both sides) to someplace on the engine head. that should also work. then take the harness grounding and connect it to the motor as well.

[MRSOUND]

So if I do the grinding, besides the coil contact do I only need to grind at one motor mount contact point on one mount or all the motor mounts?


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[knappyfeet]

So if I do the grinding, besides the coil contact do I only need to grind at one motor mount contact point on one mount or all the motor mounts?


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Simply go though all contacts with a multimeter and see if there's continuity . Powder coating needs to be removed to make good ground contacts and I would wager that your powder coated bars may not be grounded themselves.

Once you get it grounded good....your problems should dissappear.

[Dirtcrasher]

Ground off the powder at anyplace that a ground is normally bolted.

You'll be fine.....

[MRSOUND]

Only place I can see as being a ground is at the coil?


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[MRSOUND]

Grinding powder off at just the coil bracket resulted in no change☹️


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[MRSOUND]

So I ground off powder of top motor mount around contact points with frame as well as frame. Still same issue. Where around handle bar would I need to remove powder?!


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[Dirtcrasher]

^ LMAO !!

I gotta read thru this thread, who convinced you to do that!! That's funny!!

[oscarmayer]

If you had grounded to the motor you would have been fine. I told you you could do all the ground off or just ground to the motor. You went the long way.


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