so I have a wire that comes from the starter/kill switch that's just hanging there. I took a look at my friends quad (the exact same) and his is connected into the six wire connector. so i tried to hook it up into the same spot but when i turned on the quad it blow the fuse. what is this wire for and why did it blow the fuse. Its a green/black one on my buddys quad it is connected to the top right corner above the white/black wire ( if the release tab is at the top)

 

What model quad? What engine size?

Am I correct that the "starter/kill switch" refers to the left handlebar switch assembly?

Why did you try to hook this dangling wire up? What wasn't working that made you decide to do something like this?

Right now I'm searching for clues. I don't even know what the problem is yet . Let's define the problem first, then search for solutions...

 

my quad is a gio rebel t3 200cc.
yes I am referring to the switch assembly on the left handle bars.
There is nothing wrong with it now but when stuff was going wrong i always wondered if it was because of this wire. As i said before my friend has the exact same quad and the wire is hooked up. I did notice that it is hooked up to the light switch inside of the assembly when i took it apart a lil wail ago if that helps

 

So when stuff was going wrong before you suspected the dangling wire. But now it is working and the wire is still dangling. To me that strongly suggests that the dangling wire is not the issue in your earlier problems.

So out of curiousity what were your earlier problems? What did you do to fix it, or did the problem just stop for unknown reasons?

If your quad starts and runs, the battery is being kept charged, the quad shuts off with the kill and/or ignition switch, the ancillary stuff works (remote control stuff, head lights, horn, etc.), then I would leave well enough alone.

 

my earlier problems are the ones posted under gio t3 wont start ( you gave me some good advice) but it is just bothering me that this wire just hangs there I really just want to know what it is for call it curiosity lol

 

Could you take a photo?

 

so I tried to leave things as they were and what do you know it something went wrong lol. I took my quad out over the long weekend and it ran fine all weekend. I did notice that at night something smelt like hair burning I just assumed it was the pj pants I was wearing rubbed on the exhausts and was melting a bit. But when I was washing the quad the other day i notice the smell was very strong when i was under the front fender. I took the a look under the rubber that protects the head light and found that the bulbs for my high beams were melted in. here are some pics of the switch assembly the wires and the damage from the lights. I did notice that only the green wires to the bulb looked burned and melted and the bulbs still work. that mystery wire (the green/black) is connected to the light switch on the switch assembly could that be what is causing this problem

imgur: the simple image sharer switch assembly
imgur: the simple image sharer both wire connector
imgur: the simple image sharer wire connector with mystery wire
imgur: the simple image sharer backside of head light
imgur: the simple image sharer inside head light
imgur: the simple image sharer the damaged wire that i cut off to repair

 

I have that exact same switch on my quad. But I don't have that sixth wire that you seem to have on the handlebar 6 pin connector. Maybe I'm not understanding correctly. See if I'm understanding the situation:

1) That extra wire comes out of the main harness, but doesn't hook up to anything.
2) You hook it up to the extra slot in the handlebar switch six pin connector and it blows a fuse. But that implies there is a mating wire in the handlebar connector that goes to the switch. Is this correct? My identical switch does not have any wire in this slot...

And then your post gets really confusing:

A) You said "I took the a look under the rubber that protects the head light"... Note the head light is described in the "singular" context - as in *one* head light.
B) Then you wrote: "and found that the bulbs for my high beams were melted in"... Note the high beams are now described in "plural" context - as in both high beams...

Which is it? This is important... Did both lights burn up or just one? Your pictures only show one headlight...

And then then even more bizzarre: Only one of the wires feeding the bulb (or bulbs) is burnt. This is bizzarre because of connector symmetry. The bulb is fed by a source path, and a return path. All current that flows into the bulb via the source path must also return though the return path. The connections at the connector are the same pin geometry, so I would expect that if too much power is being delivered then both both pins would burn up equally. Yet you report that only one pin burnt up. That says there wasn't symmetry in the connector, and therefore one of the connections was bad - the one that burnt up obviously. Does my logic make any sense?

If only one headlight connector burnt up then almost certainly you simply has a bad corroded connection that dropped voltage with the headlight load, dissipated a lot of power and burnt up.

 

1) wire comes from the switch and doesn't connect to anything
2) I hook it up to the harness and it blows the fuse
a) I meant head lights as in both my high beam lights melted

as for the wires that hook up to the bulbs the green one was melted right threw to the bare wire and the blue wire did have some black on it but not to the point i could see the wire does this clear things up ?

 

OK. It is much clearer now. Are you head lights AC powered or DC powered? If they are DC powered then when you tunr on the ignition switch and the headlights with the engine off, they will light up. If they only run with the engine running then they are AC powered. Do you know if your buddies quad is the same way (lights are AC or DC powered same as yours...)? I'm still in the thinking and gathering information mode...