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The insulation was good @ the factory, they pulled each individual 16 awg wire through a loom. Even the splice joints were done well. The wire insulation melted because the wires overheated. This was simply a case of too much power flowing through them or someone cross connected when jumping it. The later is what I suspect most, since the ground wire for the alarm was literally melted in half. It was 22 awg wire.
Got the ignition switch back from the customer, checked my cleaning of the switch and it was good. The switch wire colors was a little surprising though.
These switches like most others only have two circuits in them: one for run and another for shut down. The run circuit was red input and red w/ white tracer for switched power (the scooter chassis switched power is black). The shut down (CDI circuit) was black w/ white tracer and black (scooter chassis ground is green).
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