wire harness modification project By gysixxer (Read 2,245 times)

[gysixxer]

Mar 15, 2012 9:11:33 GMT -6 JR said:

What colors are on the igniton key switch? On most scooters you have to put a jumper at the plug that unplugged off of the alarm itself. If you look at the Bali diagram you'll see the black/white jumped to the brown/white and yes tis keeps the CDI engine kill circuit complete. Without this jumper on the Bali you would not be able to kill the engine.

The brown/white wire goes to the key switch from the alarm plug and from the alarm plug to the CDI it's black/white. Also remember the emegency kill switch wire is black/white too.

If you have a brown/white on the key switch then yes jump it together to the black/white and tie the black/white from the kill switch to this also.

A solid brown wire usually indicates the tail, license plate and instrument light circuit.

JR

Ok so brown from key, to black white from CDI and kill switch all connected as one.. gotcha.... can u take a look st this diagram and tell me if I.missed anything???

Attachments:

[gysixxer]

Comparing ur notes to how i wired my diagram. and per what i know about my stator. I have 5 wires coming out from my stator...Yellow/White/Green...The Blue Pick up coil wire and a red one (i believe)

also, on my brakes have 2 different color wires..one set is green with a yellow stripe i believe and the other side is solid black...

but 2 g/y go to right side and 2 blk go to left side...


damn, im starting to think im not gonna make bike week

[JR]

The diagram is right on! yes you do have two different colors, look at your diagram.

The blacks go to the black on the key switch for 12vdc power.

The yellow/greens send the 12Vdc power down the line to the brake light bulb/s and the starter relay.

You have two brake handles so two blacks and two green/yellows. You put the blacks together and then tie them into the single black wire off of the key switch.

You tie the green/yellows together and put them on the single green/yellow headed to the brake light bulb/s and starter relay.

Reason why? This allows you to push either brake and start the scooter and have brake lights.!

[gysixxer]

Well, I got crackin on the harness today, I got rid of everything i dont need. I started relocating the cdi, rectifier and coil. im starting to think its going to be cramped. I drilled out some holes for ventalation for the cdi and rectifier. But it neems pretty cramped. I may just leave everything as is for now. Not sure, but well see, I have to get on it tomorrow and try to finish it. i also figured since i am adding more LED's i need to re-wire what i have already done. so YAAAAYYYYYYY MORE WIRING!!!!! I HOPE I DO THIS RIGHT THE FIRST TIME!!!!

Im gonna go buy spade connectors and do away with the plugs. and make some labels for them so i know what is what!!!

:crosses fingers:

[gysixxer]

edit....

[alleyoop]

EDIT WHAT??
I know you just wanted to bring it up to the top
I am sure it will be just fine, you got it all diagramed and it pasted the FLOW CHART TEST
Alleyoop

[gysixxer]

i edited out what i wrote. i rambled a bit, and right now lol. i dont remember what it was.
i was gunho yesterday taking it apart. seperated the wires to what i wanted. and somewhere along the lines i got lost. so i started putting the wires back where i know they went. and then there is a connector that i am missing....and i removed a wire from it. and dont remember. and its for my handle bars. but im sure ill figure it out. i think i just got tired last night and got overwhelmed. im trying to have it done by sunday...and also thinking that moving everything to the floor board may not work. but it may work in the future...i started coming up with other ideas like relocating the ignition and making it push button, and adding a dead mans switch so that no one can just start it...but thats probably not gonna happen. i think i am going to wire it up the way it was stock. and after i get this done right...my next job will be done the correct way. as in replacing all the wires with quality wires and then tucking and hiding wires..i do admit that it does look alot cleaner under the seat. still cluttered ill take a pic later...but as for the floorboard its kinda cramped and i dont think everything will fit with out some type of short happeneing....so we will see...

[gysixxer]

Where does this wore connect to??? Diagram doesn't show a yellow/white stripped wire. It's the length of the bike, I'm assuming taillights???

[gysixxer]

Okay. So I tested the scooter, she fires up perfectly. But. I cannot kill it. With the switch & not the key. I don't know what happen....only way I can kill it is unplug the bullet connectors off the stator.....any ideas? Please am trying to have it running by tomorrow...

[gysixxer]

Nevermind!!!! She is back on the road....a few minor resale full led under carriage, undertail and wheel well....hell yeah......thanks Jr...I think I may be running into an issue but not sure yet....will see tomorrow....I blew a taillight after it was done, and they arent that old, I did notice my taillights are super bright when its idling......any ideas?

[gysixxer]

Today was the worst day ever. I finish the scooter @ 330am, go for a ride around 8am. And before I got to go out. It tipped over. And scratched up the side.....brake light broke. Come home and it stopped starting. Determined the new rectifier I had is bad, stator wasn't charging, replaced and went for a ride. Screw on the pick up coil broke. And the pick up coil hit the flywheel and cracked.....had to push it home a block. Drilled out the hole, retapped it and issue was fixed. Took it out for a ride again. And went to fill it up so I can ride it tonight. And as I'm going to the gas station I realize it wE slipping and making a squeeling noise. Went home and the cvt was smoking. Took it off and all of a sudden black shavings from the belt comes out and a chunk of alluminum. I look at my case and there is a 1/4in hole in my case. It wedged and and was eating my belt......I've pretty much had it with this scooter.....I'm gonna buy the belt and sell it....to much of a headache. I missed bike week. I'm so pissed.....fml...

[JR]

Sorry to hear about all the trouble Rich. Just came in from camping a few hours ago, nice until today, violent thundertorms.

The yellow/white wire you asked about is one of the gas guage sensor wires, the othjer one is blue/white.

Hope you get her back on the road and your luck gets better.

JR

[gysixxer]

I have ad the wrost trouble with her this week....3days of pure hell..and i am actually finished with it..i actually want no more to do with it.......i started working on it saturday night @ 8pm. didnt finish till 3am. woke up @ 12p and worked till 6pm on it....heres a list of all the things that went wrong..
1. Not charging.
2. bad stator
3. bad rectifier
4. bad pick up coil
5. had to drill and retap holes for pick up coil
6. chunk of aluminum by my kickstart broke off
7. belt broke yesterday, pushed it 6miles on a partial incline....

and it tipped over, i forgot about that...


i am officially done with my scooter and the scooter scene for now....not to mention, terrilee's stupid self got me banned from scootdawg.....granted she got me when i was angry. but she didnt need to threadjack my forsale thread and instigate.....

so im selling my scooter...

[JR]

Hey Rich take a few days and do something else and then look at things. Still planning on helping with the friends new forum?

JR

[gysixxer]

the scooter is running now...but the belt broke....has nothing to do with taking a few days. im done with it....its a freaking nightmare....i missed bike week. i dont know if i want to do anything scooters anymore....i just cant take this shit anymore....my bike spends more time getting worked on then i do riding it....if i go back to riding, im probably gonna get a real bike....or if i do scooters, im gonna get a honda ruckus.....get the reliablility....will see...but as for now..im over it...