butchered wiring harness By rangerdaver91 (Read 17,667 times)

[rangerdaver91]

Hello every one , I am new to scooters and the forum. I have a scooter that was given to me, it is a 2003, it looks like a Yamaha Vino classic, and says "licensed by Yamaha" on the Variator cover,I have been around motorcycles most of my life and have never seen this before. The sticker says manufactured by Yaxi Motors, it has a 50cc 1E40QMB 2 stroke engine. A man bought it for his daughter, it quit running and her boyfriend decided to fix it one evening. This is where the trouble started, without them knowing it he decided he should smoke a bunch of crack before and during the repair. When they found him still at it the next morning he was wacked out of his head and the wiring harness was totally butchered to put it lightly.He had cut, chopped and hacked his way thru the entire harness, loosing a lot of what had been hacked off. I took the scooter to my local scooter shop and was told that it was not a Yamaha and they had never heard of Yaxi motors and the harness was way to far gone for them to fix and I would need a complete new(or used) harness and that they had no idea where to get one. they also told me that most any Chinese scooter with the 1E40QMB 2 stroke engine should work. I have been surfing the web all day and cannot find one.PLEASE HELP !!! Thanks Dave

[alleyoop]

Check out the wireing harness available on ebay.
Alleyoop
.ebay.com/sch/i.html?_nkw=50cc%20wire%20harness&clk_rvr_id=352696913805&adpos=1s3&MT_ID=69&crlp=10578456164_2416792&tt_encode=raw&keyword=50cc+wire+harness&geo_id=9232&adgroup_id=3143106164" rel="nofollow" target="_blank">.ebay.com/sch/i.html?_nkw=50cc%20wire%20harness&clk_rvr_id=352696913805&adpos=1s3&MT_ID=69&crlp=10578456164_2416792&tt_encode=raw&keyword=50cc+wire+harness&geo_id=9232&adgroup_id=3143106164

[JR]

This should be your style of scooter;

.roketa.com/product/2610/0/59067.shtml" rel="nofollow" target="_blank">.roketa.com/product/2610/0/59067.shtml


The Vino like a lot of copies is a Vespa style scooter.


Now when it comes to buying a exact wiring harness for scooters it's tough and what's even harder with yours is no one has heard of it? Man I spent awhile trying to locate this scooter by the name you gave. The scooter will have a manufaturer tage on it somewhere with the VIN number and name of the company that built it, if you can give us that it might help?

Now there are several wiring configurations on Chinese 2T scooters just like there is on $T ones so since we don't have a clue to exactly what it is then we're shooting in the dark on a wiring diagram but go to this link in our tech section;

thescooterprofessor.proboards.com/index.cgi?board=twot&action=display&thread=784

Click on this diagram and let's see if it will match up to yours?

Eton Beamer/Matrix Wiring Diagrams 04-06 07-08

Now when you say butchered what areas and if you can take some clear pictures and give me some wire colors of the areas then we may be able to repair this harness? Even if we need to buy a new one and try to get one to fit I'm still going to need pictures of what you have at places like the stator and CDI among others to try to match up a harness as best we can.

Also Welcome to the forum!

JR

[justbuggin2]

Jr is the forums wiring guru he will be the best help for you and get the pics that he asks for so he can do his magic

[rangerdaver91]

Ok I have been really busy, I have almost everything working, horn, turn signals, brake light,Fuel gauge and the starter works also. I still don't have head light or tail light.I have been tring to find a wire that puts out voltage when key is turned on to hook my head and tail light to, hope thats the right thing to do. While testing wires I found a 2 pin connector, it has a blue/yellow wire and a green wire, I only have a test light , but when I checked it with the key on it had low voltage, my test light lit up very dim, not bright like when touched to a battery. even tho the wire colors dont match, could this be my auto choke connector? The plugs do match.There is another two pin connector that has a green wire and a yellow wire that I have no idea where it goes, but would also hook to auto choke plug if thats where it goes There is also one red/white wire coming from harness that I am also lost about.So now I need to figure out how to hook up the CDI and coil and get some fire.The CDI has a 2 wire connector red/blk and grn/yell they are plugged in.From the CDI, red/blk goes to blk/red and grn/yell goes to white/grn from engine wires.From the engine the wires are: white/red female bullet connector unhooked,a 3 wire connector with a blk wire a yell/red wire and a white wire, the plug is unhooked. For a total of 6 wires coming from the engine.From the CDI wires are : red/blk and grn/yell with 2 wire connector which is hooked to engine, then a red/white wire with male bullet connector unhooked,a blk/white wire with female bullet connector unhooked,an orange wire with female bullet connector unhooked ,and a blk wire with male bullet connector unhooked, for a total of 6 wires coming from the CDI. The coil has 2 wires blk ground and a blk/yell wire both unhooked.I have no idea where to hook the blk/yellow. I cannot read a wiring schematic and don't have a clue what I'm looking at, guess Im a hook this wire there and that one over there sort of guy lol.Well crap, went to take some pics and the battery is exhausted on my camera, will post some later.

[JR]

Ok some of this I know by heart and the pictures will help a lot and what I need most is the wires spread out on the CDI and the exact colors. 2 stroke CDI's a lot of the time have a pigtale on them and the wires plug in to the stator, coil and kill switch.

So lets try to sort them out by what I know needs to happen to make it run? Also the head/tail lights run off of the stator and not off of a hot wire with the key on, simply put they will not work unless the scooter is RUNNING. Don't worry about the lights right now, lets get her to run first.

The two wires from the engine stator that are pluigged up to the CDI are correct, they are the AC feed to the CDI and the signal pulse wire from the stator to the CDI.

Now I'm going to try to sort these out a wire at a time. The 3 plug connector from the engine goes to the R/R (regulator/rectifier) and autochoke. You got to locate the R/R also.

Black = ground
yellow/red = AC feed to autochoke
White = AC feed to R/R


The white/red female bullet connector from the engine plugs into the red/white male bullet connector and also goes is another AC feed from the engine to the R/R

Now the black/white on the CDI plugs into the black/yellow on the coil.

Of course we know black is ground on the CDI and coil.

Orange on the CDI is the engine kill wire and it's going to tie in and run to the igniton key switch and engine kill switch on the handle bar. It may or may not plug into the same color wire going to these two places. The Chinese change colors a lot.

If the stator, coil and CDI are good then this should get it to run.

Again get me the pictures and I'll be out of pocket tomorrow and a lot Friday but I'll check in some on the hotel computer.

JR

[JR]

s1079.photobucket.com/albums/w504/rangerdaver91/?action=view¤t=DSCN0296.jpg#!oZZ9QQcurrentZZhttp%3A%2F%2Fs1079.photobucket.com%2Falbums%2Fw504%2Frangerdaver91%2F%3Faction%3Dview%26current%3DDSCN0284.jpg

Rangerdave hit the above link and this brings you to one of your pictures in your album, on the right you see links, click on the bottom one and it will copy then paste it on your posts on this forum just like I did and your pictures will come up.

Now I'm going to be gone today and I'll study these tongiht and we'll get this scooter going. JR

[rangerdaver91]

JR, I just noticed that you are from Petit Jean Ark. I grew up in Clarksville Ark. I'v lived in Russellville, Dardanelle, and up on Crow Mountain, I went to Petit Jean Votech in the early 80's Morrilton was the closest place to buy beer back then lol. Small world huh. Thank you for all the help, without it I may never get this thing running again. I will be at Ky lake this weekend, but will be back Monday.

[JR]

A Arkie transplanted to the "show me state?" Man you need to come home, used to be married to one of those Missouri girls and they're mean!

I was originally born and raised in SW Arkansas near a little town called Lockesburg in Sevier County.

OK I've done some work on this scooter with your pictures and I'm also going to post the other two pictures of this brand of scooter and while I consider myself a good googler as the guys call me this one to say the least has been tough, like it doesn't exist but we can't deny it's existance because of the pictures below;







Just like he said licensed by Yamaha and I've spent at least 8 hours using search engines for information on this scooter, didn't expect to find a manual or wiring diagram which remeinds me do you have a manual with a wiring diagram in it? If so let me know and we'll make arrangements for me to get it. Sometimes it just saves time if the diagram is original and not a generic, either way we'll figure it out.

This is the only information on this scooter I've found and it's a sight that at least lists Yaxi Motors;

.mopedworld.com/MopedScooterParts.htm" rel="nofollow" target="_blank">.mopedworld.com/MopedScooterParts.htm

I don't even find any information on the VIN number.

Oh well so what I've done is label these pictures and on some I've numbered wires that match by what I know that's common on 2T scooters. The pictures with numbered ??'s I'll ask for information and also may have you do some tests to either verify what I think it is or to find out what it is.

Now since you mentioned you've got it turning over that means you've got a good hot charged battery and it's hooked up and with no meter we can still use your test light to verify some wires but you may end up having to get a cheap multimeter at Wally World that will read ohms for some, we'll wait and see. Also did the previous owner mention why it quit running?

Now on a lot of GY-6 scooters the wiring is more uniform, for instance the black/white wire most nearly always is the engine kill wire and I have several 2T wiring diagrams and while they nearly all run the same way not one of them hardly use the same colors, it's like they sweep up the scrap wire off of the floor from wiring 4T's and use it on the 2T's seriously!

The 2 bangers are different to say the least.

So here's the first picture and questions picture A



You mentioned a single red/white wire and I labeled it ??1 and does this wire have a male bullet connector on the end? In your picture that is not clear? Also in the harness can you determine which direction this wire heads as in does it go to the front of the scooter or back? Reason I ask is I suspect this is the engine kill wire that goes to the ignition kill switch and if it has one the engine kill switch on the handle bars?

So here's how we can test it.

(1) turn key on
(2) hook one lead of your test light to end of red/white wire and other to the positive post on the battery
(3) turn key off, if this is the engine kill wire the test light will light up.

Yes I know this sounds weird but the engine kil wire grounds out the CDI and with the key off it is a ground wire that's why I wanted you to turn the key on first. Now to be sure let's test the engine on/off or kill switch on the handle bars and here's how you do that;

(1) turn key on
(2) hook one lead of your test light to end of red/white wire and other to the positive post on the battery
(3) turn engine kill wire to off position if this is the kill wire to the CDI the test light will light up again.

If this is that wire I know where it hooks up and I'll tell you in another picture to come.

In this same picture you see the pigtail I labeled ??4. I need to know the exact wire color/s and an idea of where it heads to in fact if you locate something it goes to take a picture I have my thoughts but will wait until I know more information.

To keep this from being too long I'll start another post with pictures.

JR

[JR]

OK here is picture B;



This is the coil and it has two numbered wires #2 which appears to be black/yellow and #4 which is black and here's where they should plug into in picture D;



#2 in picture B plugs into #2 in picture D which is the black/white wire.
#4 in picture B plugs into #4 in picture D which is the black wire.

The black/white sends voltage to the coil and if you notice the coil is bolted to the frame and the black wire with it, this supplies ground to the CDI.

Now while we are looking at picture D we will also hook up two more wires, now look at picture C:



#1 in picture D hooks into #1 in picture C.

Now this leaves us with wire #3 the orange wire in picture D and here's where the first test I gave you comes in. If the red/white wire we tested IS the engine kill wire it now becomes #3 in picture A and hooks up to #3 in picture D. If not we've got to find the engine kill wire.

Time for another post.

JR

[JR]

OK that leaves us with pictures E, F and G we'll address them in order first E;



It appears to have 3 wires and one is yellow and the other green? Need to know the exact number of wires and the color/s. Also can you trace it out to where or what it goes to?

Now picture F;



This is a male plug and appears to have 3 wires also and a green and blue is clear but not the third wire? It may very well plug into the plug in picture E but again need number of wires and color/s and an idea of what it goes to?

Now picture G;



You see the 3 plug and I have it labeled as "should go to R/R" and I need to know the color of the three wires, they are not clear in the picture.

Now I also have a ??2 and ??3 labeled, again how many and what color/s and where do they go? We already know what wire #1 goes to.

Now if we have the CDI and coil hooked up correctly and they along with the stator are good then we should have a spark on the spark plug. Doesn't matter about the R/R and lights right now with a good stator, CDI, coil and spark plug along with a good fuel supply the scooter will run.

After you hook up all these wires you need to pull the plug and put it on a good ground and turn the engine over and watch for spark.

JR

[rangerdaver91]

Ok here goes.
Picture A, ???1 , Kill switch wire(red/white) runs to blk/white wire coming from key switch. Tested and confirmed. 2 wire connector ??4 : wires are grn and blue/faded yellow stripe.goes to a light bulb on the chrome cover under handle bars, has a red lens cover, I figure its the high beam indicator ?

Picture E, 3 wire connector : wires are grn(ground), Yellow , and Dark grn. Dark Green goes to R/R.

Picture F,This is a 2 wire connector : wires are grn(ground) and blue/faded yellow, can't find any plug to connect to.(unhooked as of now) This is the wire that I thought was putting out low voltage.My brother tested it and it has 12 volts with key on.Where to plug it in ?

Picture G, should go to R/R : wires are Dark grn , yellow , grn(ground) I have this plugged into 3 wire connector from stator. ??2 is this connector. ??3 comes from Carb. 2 wire connector : wires are grn(ground) and Yellow. There is a 2 wire Female connector that also has grn(ground) wire and a yellow wire. I have these plugged into the carb. I believe this to be the auto choke ?

My brother tested the coil via how to test a coil off the internet and says its bad. I have a new one ordered and should be here Tueday.

This is how the wires are connected as of right now. Still no fire, hopfully new coil will fix.
The two wire connector from stator is pluigged into the CDI 2 wire connector.
The white/red female bullet connector from the engine plugs into the red/white male bullet connector from the CDI.
black/white on the CDI plugs into the black/yellow on the coil.
black on the CDI to black on coil.
3 wire plug from Stator(Picture G, should go to R/R) is plugged into the 3 wire plug from harness(Picture E)
Orange wire from CDI is plugged into red/white from harness which goes to blk/white wire from key switch.

After I get this beast running, I want to put no rev limit CDI on it.(Yamaha JOG Zuma Minarelli 1E40QMB performance race ignition CDI) from ScrappDogScooters. Will you be able to show(tell)me how to hook this up after we have our current issues fixed ? Or recommend the one you feel I need?
I did get a manual on CD, but it is for a Yamaha Vino 50 YJ50 2001-2005. I can mail it to you if you think it will help. Engine #'s NF1E40QMB and 990904383 stamped on housing above rear axle.

[JR]

2 wire connector ??4 : wires are grn and blue/faded yellow stripe.goes to a light bulb on the chrome cover under handle bars, has a red lens cover, I figure its the high beam indicator ?

Most of the time the high beam indicator is blue? A lot of 2 strokers have a oil level light and if this is the case on this scooter then you will have an oil sending unit on oil tank if it has one. Since you mentioned the Yamaha Vino YJ50 manual I looked at it because I already have this manual in the Yamaha manual section of the tech library. This manual shows such a light. This manual also has the wiring of the Yamaha scooter in sections and it's possible that it matches your scooter to the letter?

Picture F,This is a 2 wire connector : wires are grn(ground) and blue/faded yellow, can't find any plug to connect to.(unhooked as of now) This is the wire that I thought was putting out low voltage.My brother tested it and it has 12 volts with key on.Where to plug it in ?

Some scooters have a extra accessory plug in case one wants to add something electrical to their scooter. At this point don't worry about it, let's get it to run first.

??3 comes from Carb. 2 wire connector : wires are grn(ground) and Yellow. There is a 2 wire Female connector that also has grn(ground) wire and a yellow wire. I have these plugged into the carb. I believe this to be the auto choke ?

This was my thought also and I believe it to be correct.

My brother tested the coil via how to test a coil off the internet and says its bad. I have a new one ordered and should be here Tueday.

In the Vino 50 manual it gives specific test values for the coil and how to test it also. But as I stated before we need a stator test to see if it's sending voltage to the CDI?

Hook up the volt meter to the wire (black/red) from the stator and turn the scooter over to see if you're getting AC voltage. No need for a new coil if the stator doesn't supply electricity to the CDI.

Also test the other wire on that same plug which should give a very low AC voltage reading.

After I get this beast running, I want to put no rev limit CDI on it.(Yamaha JOG Zuma Minarelli 1E40QMB performance race ignition CDI) from ScrappDogScooters. Will you be able to show(tell)me how to hook this up after we have our current issues fixed ? Or recommend the one you feel I need?

No problem at all.

JR

[rangerdaver91]

Well my brother used his multimeter and checked out the blk/red wire from the stator going to the 2 wire connector to CDI ,the second wire is white/green. From blk/red to ground while cranking engine there is nothing, same thing with the white/green wire to ground. But when he checked between the blk/red and the white/green from stator there was around 75 volts AC while cranking the engine over. The single white/red wire coming from the stator also puts out some AC voltage while grounded and the engine is cranked. I also removed the licensed by Yamaha cover, and under it is another Variator cover and it says NANFANG on it. And also there is a pair of wires coming out of the oil tank a blk wire and a green wire with a 2 pin connector that could be plugged into our mystery plug with blue/faded yellow and a green wire, maybe the oil light ? I do plan on disabling the oil injector and mixing my oil with gas. Hope this gives us some more clues to getting this thing running.

[JR]

Stator is good and that eliminates that possibility. Aslo found the oil level sensor and it will plug into the red lense light and if you wanted to test it just drain the tank and it should light up.

Now if that coil will come in!

JR