wiring harness is driving me mad!!!! By lazerorca (Read 23,991 times)

[lazerorca]

I was told... oh it's easy... just match it up to the old one... well... if only it were that easy. the harness I got came with no schematic... the front end of my scooter is a complete mess it looks like. I have colored wires on my harness that are not in the front end... and vice versa. I tried just "matching up colors" kindergarten style making sure my fuse was in. blew two fuses and voltage regulator got a bit warm. I'm lost with this. The old harness looks quite a bit different from the "generic" one that I got. The scooter I have is a 50cc Taizhou Chuanl. any suggestions?

[alleyoop]

Welcome good you made it over here,
JR I am sure will see your post I emailed him to let him know you came on for help. Also it will help a lot if you can take pictures. I am sure he will ask for pictures to see what you have.
Alleyoop

[JR]

First of all welcome to the forum. looks like this company has two 50cc models and they look like the typical Chinese scooters;

.longboamerica.com/home.php?cat=1" rel="nofollow" target="_blank">.longboamerica.com/home.php?cat=1

I see two 50cc models and more than likely they wire the same. Now as for the harness you got, Which one did you buy with nom istructions?

eshop.mainelyscooters.com/product-category/cat-electrical/cat-harness/

I'm going to need you to help me help you with wire colors and plugs and info.

I'm not worried about the scooter, I know what goes to what. For instance lets make sure it's the typical 50cc set up?

Left side on the handle bars = these switches

horn
hi/lo beam
turn signal

Right side of handle bars = these switches

emergency kill switch
start button

Then of course the ignition key switch is mounted somewhere in ther front area.

Get back to me and with some information about your harness and some wire colors I can figure this out and get you going.

JR

[lazerorca]

here is the harness that I bought

eshop.mainelyscooters.com/product/139qmb-generic-wiring-harness

that is the config on my handlebars as you described it... it is raining a bit now so I can't take photos... i have it under a tarp...

But I can describe to you one aspect of this that i am trying to figure out...

On the back of my ignition switch, I have this wiring configuration starting at the 12 oclock position and going clockwise: Green, Black, Black/White, Red, Green... 5 wires

The suspected bundle of wires that I think goes to the ignition from the harness has a separate fuschia/white wire and a connector with red, black, and green... 4 wires

One clue I can offer is that the old harness had a black/white wire hooked up to the CDI where the fuschia/white wire is now... I assume that this fuschia/white wire will take the place of the black/white wire on the ignition as well...

[lazerorca]

ok here is a detailed description of the wire colors and where they are coming from.

right side of the handle bar has the starter button and the switch for killing the engine... we have red/yellow, green, black/white, black

left side: hi/lo beam, horn, turn signal

light blue, dark green, gray, black, orange, light green (i'd also like to note that dark green is matched with yellow on the other side of the connector...)

both sets of brake wires are brought together to one set... green/yellow, black

will list rest later... gf is worrying me...

[JR]

Ok the 5 wires to the igniton switch is odd but it's easy enough to figure out so lets start with some basics of what is always 99% true on Chinese scooters and then we can take it a wire at a time until we get this thing back on the road. You'll also get an education on how a scooter's electrical system works.

Igntion key switch

Red = 12Vdc from battery it will be fused so trace out this wire and make sure it's right
black = 12Vdc with key in the on position
Black/white = kill wire to CDI
Green = ground
Now on your switch you have two greens and this could be a wire used for the kill switch or not? We'll cross that bridge when we get there.

Now this black wire off of the ignition key is used for the brake lights, horn and fuel gauge and to the turn signal flasher, on a 50cc that's it unless you have a volt meter, if so then the black goes to one side there.

You have two brake handles and they are always put together with a little split two to one connector and the other side of the brake handle is as you mentioned yellow/green and these hook together the same way in a two to one connector. The yellow/green goes to the brake light side of the bulbs and...........to the starter relay to start the scooter. When you turn on the key and press the brake handle you make the brake lights come on and at the same time send 12Vdc+ to the starter relay.

So you must hook the black wires to each brake to the black wire off of the igntion. You then use the yellow/green to each brake handle and then make sure it goes back and hooks to the brake light bulb and to one side of the starter relay.

You must run a black from the black igniton wire to the black wire on the turn signal flasher, it's the little round thing strapped on and has two or three wires to it

Black to black
Gray to gray on turn signal switch
Green to green(ground if it is 3-wire)

On your left side switch is the black and light green =

Black to black on ignition switch
light green from switch to horn


Turn signals =

Gray to gray on turn signal flasher unit
orange to left side turn signal bulbs front and rear
light/blue to right side turn signal bulbs front and rear.

Now it was mentioned you don't have a way right now to go get some more connectors and if your plugs and the harness provided plugs don't match then you're going to have to cut them off and splice the wires together the best you can with black tape or crimp connectors or get a matching harnesss. We can make this work but it by your description doesn't look like plug and play.

I've got to leave for a spell that's enough to digest at the moment and we can work on the other wires later if you can match these up and then we will proceed.

JR

[lazerorca]

thanks... I will take a look at it later. I will let you know what I get accomplished.

[lazerorca]

well the rain is putting a damper on my scooter work today ugh

[JR]

Sorry to hear that, send some of the rain here, my garden needs it! But not the ugly storms!

I'll watch to see how it goes and we'll go from there.

JR

[lazerorca]

I bought a multimeter today to try and trace wires... well everytime I plug up the terminals to my battery... the tamp fuse breaks... what gives?

[lazerorca]

starting from rear... with the lights... green, yellow/white, blue/white match up to a plug, so does green, yellow/green, brown... on the harness I have 2 bundles left... (green, light blue), (orange, green) the bundle left from the back harness is (light blue, orange)...

to the CDI I have fuschia/black, fuschia/white, green/fuschia, yellow/blue, and green... I just plugged them in assuming they were in the right config

to the choke I have yellow, and green/black which matched up to my harness...

to the coil I have fuschia/green and green

now to the stator... what I have on the harness doesn't match cleanly... I have blue/yellow matched to fushia/white and fuschia/black to fushia/black... the plug from the harness only have yellow and white while the plug from the stator has white, yellow, and green...

I have a random plug that I haven't found a match to... it is a fat red/white wire... it comes from the start relay I believe... I also have wire that is green/black... doesn't match to anything either...

I believe this next plug goes to the regulator which originally was mounted on the front of my scooter... it is red, white, yellow, green... has a seperate green wire coming from it as well that I think is a ground wire... to the starter relay I have a fat red/white and fat red wire hooked up... also a red/yellow, and green yellow hooked up... that is all that I have hooked up...

here is what I have at the end of my harness to hook to the front end harness... listed by how they are bundled...

1. light blue, black
2. green, orange
3. light blue, green
4. green/yellow, black
5. green/yellow, black
6. green, white, blue
7. white, blue on one connector and green, light blue, blue, brown, orange, blue/black
8. on a blue connector, I have red/yellow, blue/black, black, brown, yellow, green
9. on a male connector I have blue, blue/white, light blue, orange, yellow/white, brown, black... with a separate green... I suspect this is the one I will need to use now sure...
10. I think this goes to the starter... fuschia/white, red, green, black

coming from the front end harness... here are the wires that need to be matched up...
1. on one connector I have blue/white, green, light blue, red/yellow, orange, black, yellow/white, and yellow... on a separate connector I have green and black/white... then there is another connector where the old harness had a green/black wire hooked to it... I have no clue what it is... the wires are running to this gismo have braided covering... they are black and white and run up close to the horn

[JR]

starting from rear... with the lights... green, yellow/white, blue/white match up to a plug, so does green, yellow/green, brown... on the harness I have 2 bundles left... (green, light blue), (orange, green) the bundle left from the back harness is (light blue, orange)...

All greens are ground
Yellow/white & blue/white go from gas gauge sending unit in tank to back of fuel gauge
yellow/green = brake light
Brown = tail light
light/blue = right turn siganl
orange = left turn signal


coming from the front end harness... here are the wires that need to be matched up...
1. on one connector I have blue/white, green, light blue, red/yellow, orange, black, yellow/white, and yellow... on a separate connector I have green and black/white... then there is another connector where the old harness had a green/black wire hooked to it... I have no clue what it is... the wires are running to this gismo have braided covering... they are black and white and run up close to the horn

Blue/white & yellow/white go to fuel gauge
all greens = ground
light blue = right turn signal
orange = left turn signal
black/white CDI engine kill wire
black = 12Vdc from igntion key
red/yellow = engine start button
yellow = 12v from R/R


Now I've stopped here because it's apparent the the new harness doesn't matc to you old one and now I've got to get some answwers about you old wire colors and some about the new.

Also I don't have a clue as to what fuschia is so please give me the color in simple terems for me.

Coming off of your stator your wires what are they? You should have a 3-wire plug and two single bullett connector wires as follow;

3-plug = green, yellow, white

bullet connector black/red = AC feed to CDI
bullet connector blue/white or read/white = coil pick up sensor wire to CDI

So the new harness plugs that you have plugged into the CDI right now what colors are they? Two of those wires will have a male bullet connector on the other ends that will plug into the female ends on the stator again what color are these two single bullet connector wires?

You will have 3 more wires on the CDI =

Black/white = engine kill wire
green = ground
yellow/black feeds coil

If the new harness has no black/white kill wire then we got to run a seperate wire or use another wire in the harness if one is available.

R/R wires will be;

yellow from stator
white from stator
green= ground
red = wire to go to battery for charging and 12Vdc to ignition key switch


Now here is also some other info I need to start matching wires on the front;

Hi/Lo headlight beam switch, how many wires and their colors
horn switch wires and colors
turn signal switch = gray, light/blue and orange just confirm that please

Other side this is a little tricky? On the start button I know beyond a shadow of a doubt one of the wires will be red/yellow. What I need to know is the other color wire to it and where it goes? It's possible no matter what color it is it just jumps right over to the emergency engine kill switch wire and is fed there?

I am also sure that the emergency kill switch will have a black/white wire and a green ground wire but again I want to know if it stands alone or is jumped over to the start button.

Know this is frustrating but we are making some progress.

JR

[lazerorca]

I believe fuschia = red...

right side of the handle bar has the starter button and the switch for killing the engine... we have red/yellow, green, black/white, black

left side: hi/lo beam, horn, turn signal

light blue, dark green, gray, black, orange, light green (i'd also like to note that dark green is matched with yellow on the other side of the connector...)

both sets of brake wires are brought together to one set... green/yellow, black

I finally have some photos

This is from my new harness I believe they are the bundle of wires that goes to my ignition



Here is a picture of the back of my ignition...



Here is a pic of the back of the scooter where the harness hooks into the back harness for taillights, fuel sensor, etc etc.. Notice that orange and light blue have no match... I do have 2 unmatched bundles from my new main harness... they are (light blue and green) and (orange and green) wasn't sure if I should just match them and what I should do with the leftover green wires...



Here is a pic of the wires for the stator... notice that there is a three pronged connector with yellow, white, and green while the connector from my new harness just has yellow and white



This is a pic of the CDI. There is no black/white kill... it is replaced by another wire it is replaced by another wire (I believe red/white)



This is a pic of the coil... i believe it is hooked up correctly



These two wires I am a bit unclear as to their purpose... if someone would clue me in that would rock.



I believe this goes to the voltage regulator. I'm not sure if I'm supposed to strap that green wire I'm holding to the body of the scooter. also the voltage regulator was originally mounted up front.



This is a pic of the battery and starter relay... I think it is hooked up correctly



This is the quagmire of sh*t on the other end of my harness



This is what I somehow have to figure out where to hook up everything to the front end harness..



This is horn and blinker unit (and where regulator used to be)... and a gismo I'm unsure of below the blinker unit that has a braided white a black wire with bullet ends...



This is a pic from behind the instrumentation panel



I hope these photos are helpful... if you need more photos just lemme know. I can also shoot video.

[JR]

Great photos and let me work on each one plus the wires and I'll take notes so I can give a complete report and we can start wiring this baby up. Glad you took a picture of the ignition switch.

Question? do you have a volt meter and know how to ohm a circuit?

I will get back and it may be tonight but I will do so.

JR

[lazerorca]

I have a multimeter but don't know how to "ohm" a circuit... also I forgot to mention my tamp fuse keeps blowing whenever I hook up the battery.