YY250T Cooling fan prob. Update 4.sep.2012 By slovenian (Read 1,568 times)

[slovenian]

I'm so frustrated with this scooter! Every time i go to fix or adjust a thing, some shit always goes bad! I don't know is it just me, or my lack of knowledge or I'm just clumsy... (sure my English is bad)


The problem started when i tryed to put a different lamp into rear light. I put them in and started the bike, everything was OK, the bike started and the lamp was shining so i killed the engine, and took the keys out, and then went adjusting other lamp for the rear lights!

Yeah both were dead! I noticed that one lamp had 12v and 3W, and another had 12V 5W. So i thought its OK to put the "car type" lamp in... (they are just the same)

So i put the second lamp in ( now both were 12V 5W), and when i put the second I tryed to turn the key, and when i turned it I noticed that the voltage output is smaller (light on the dashboard and front light were very dim!!) so i took the key out and removed the lamps, when i was removing the lamp i saw i quite big spark at the lamp "connector" (where the lamp i goes in).

Next i tryed to turn the key and no feedback I got! Even the gas indicator didn't move! Clock is also dead!

So i checked the fuses next to the battery, and the were OK!
I also changed them just to be sure! NO SUCCESS!

I tryed to refill the battery with a car charger. THE BATTERY IS FULL! still NO SUCCESS!


Is anything left to check??? another fuse box???

Can anyone explain to me what exactly is CDI, and can it be that my broke?


Where can i start to check to errors, and how can i solve my problem??

I'm offering a bear to anyone that helps me solve the problem (pay pal) ;D



EDIT: after alot of reading, I think that main fuse could went bad.... how can i check it, and where to find the main fuse?? I was looking at the electrical diagram and i just dont get it... me and electrical stuff are strangers!

Any kind of assistance would be appriciated

[JR]

First of all Welcome to the forum. Sorry for my late reply but left very early this morning to take care of some family business.

Also two other things, don't worry about your english we'll do just fine communicating and the other is this is a free forum and we help people cause we like to and could never charge for any help we give.

Now since you've mentioned changing the fuses in the fuse box and still have nothing? Ok I suspect your from Europe and this scooter has four different set ups as far as wiring goes and here is the tech link to those diagrams:



thescooterprofessor.proboards.com/index.cgi?board=250g&action=display&thread=430

Now yours should be the last on the Euro version and you'll see the different fuses but there is one other main fuse. Now I'm not sure where exactly it is but I can tell you where to look according to the other versions.

If you look at the wiring diagram you'll see a 20A fuse on the stater relay area. The starter relay/solenoid is right above the muffler behind the side panel. This fuse plugs into the relay and lots of time they also have a spare fuse in the holder.

If this fuse is dead you will have not voltage going to the key switch in fact the scooter will be dead.

Now on some of these they put this fuse right by the battery for easy access so check that area too.

So check out these two items and get back with us and we'll see if we can get you up and going.

JR

[slovenian]

HI

Thank u for your input!

Will report back!



Be safe an well.

Damien

[slovenian]

Update.

We found the main fuse right of the battery, cause the shop didn't have any, my friend fixed the old one with a small wire...

Scooter started right away.

But now I have a new problem with the cooling fan. The heat gauges are at red and the fan just isn't working!!
I tried the cooling fan fuses and they are ok!

Wtf, I'm so mad that I'm ready to burn this Chinese piece of shit...

Do u have any ideas JR?


The for the help, I really appreciate it

[alleyoop]

You need to replace it with the correct fuse, otherwise things can start to burn up because to many amps are being drawn. Just go to the auto parts store they will have the fuses.
Alleyoop

[JR]

OK I don't know if you have any of the plastics off but if the fan isn't coming on here is a list of possible reasons why:

Bad thermoswitch on radiator that closes at around 167F
Bad fan
broke or loose wire connection
bad fuse holder
bad fuse
air in cooling system

Now the bad or broke wire could be in one of several areas. First thing to do is turn the key on and use a multimeter set to Dc volts and make sure you have 12Vdc+ at the fuse box where the fuse plugs in and also you may want to pull the fuse box out and inspect it thoroughly for problems and they do have problems at times. If yopu have no voltage then for sure you've got a problem.

If all checks out well with the fuse box and you are sending voltage to the thermoswitch then you need to check it out and first thing is to jump the wires on the thermoswitch with the key on and if the fan comes on then you probably have a bad switch unless..............

you have air in the cooling system. If you do then lots of times the fan will not come on. We have a engine burp how to in the tech section that expalins how to burp or get the air out of the system.

Like with all gremlins one has to use the process of elimination sometimes to find the problem.

JR

[slovenian]

Hellow its me again¨!

I just returned from vacation and started to work on my scoot again.

So i took apart the scoot (all plastics) and take a look at the scoot from inside and its electrical wiriing: I checked the fan, its working! I checked, the termostat, its working! And I still got no working fan. so I checked the wiriing below the fuse box, I took it out and checked, after someplaying with the wire, the fan was acttualy working, I was so damn happy!

So i took the scoot back together, and drove to work this monday. I had a huge smile on my face the whole ride to work.... and then the gremlins hit my scoot again.

In the middle of the way i checked if the fan is working, IT WAS!
But when i parked my scoot at my firm. my cowerker saw my scoot is leaving water behind!!! thw watter was exiting from the ( plastic stuff where the coolant goes in, near fuel entrence!

MY smile on the face was quickly gone!!!!

I waited for the scoot to cool down, and refilled the watter ( had no coolant) and checked that there is no leek at the hooses! there was no leak! and tryed to play with the wires(like at home prior), no succes!!!

My coworker is electrician and he checked that the fan is getting the electricity! The fuses are OK, and letting the electricity to the fan!

He said that only 2 posibilities are the broke fan (I doubt) or the bipolar fuse, but i think that it is air in the system!!! the watter is circulating!! the fuses are OK! the fan and termostat are working!
all electricity connectors are ok!

I did not flush it!!!

I didnt find the bolt to drain it!!!

I was just reading your post JR and found the picture of the bolt.

What are ure thoughts on this matter JR? Thanks for all the support fellow forumers !!

Sorry for my bad english (im from europe)!


Take care and have a safe ride!


Damien

[slovenian]

Update:

I did the burping of my scoot (flushed the cooling system with water, following JR's guide in tech section).

I repeated the process 3x times, and the fan still doesn't work and the scoot is overheating!

Fan=working!
Fuses=working!
Wiring=good (connectors)
Thermostat=working (i boiled it)
The fan receives the electricity! The pump is working!

What else could it be??? I'm so desperate!

I have bought my scoot a month ago and i took the scoot apart 4 time by now! I'm ready to sell it or burn it!

Can anybody give me some advice what to do?



Take care and have a nice ride...

Damien

[JR]

After each time you burped it did you have to add a little coolant? If so it still has air in it. If not then we need to see if you have a bad thermostat that is stuck.

Sometimes the burping process is simple and a one time thing but I've see others have to do it several times to finally get all the air out and let the scooter get totally cold between burps, this allows all the air to work it's way to the top of the radiator.

JR

[slovenian]

Thank your very much mate for the reply! You indeed keep my morale up! I relay dunno why.


First I'm gonna try to get a scooter home from work! I cant get a van ( i can only rent it), but because of organized crime there is a new procedure that takes time and nerves to get an van.

Ill drive it home! From bar to bar lmfao!! From cafe to cafe, and waiting to coll down! I need do make 14 miles to get the scooter home, i think 4 stops will be just fine.


Burping... Yes, i needed to add some water ( ididnt use coolant, i was just trying to get it to work)...

A
I just need to know one thing, do i keep the plastic "bottle" in which u fill the coolant in (left of gas filling hole) closed.. So.. When I'm filling a coolant in the radiator (under the seat) does the coolant fill hole must be closed?? (that black rubber cap)


Cause when i was adding the coolant after burping the scoot was leaking the watter from that spot (near gas cap)(it was leaking very slowly through the top of the opened "bottle"...


When i drained the system i try-ed to blow in it for couple of times, and i could sense that i has still watter in! I could sense the watter in that "bottle"! when i drained the whole system the "bottle/coolant tank" near gas tank was actually half full. and i just couldn't get it to drain!

I'm sorry to get complicated when I'm writing, but I just want to explain everything, cause maybe its important!


So ill try to burp it couple more times!!! Is getting it bone cold really that important? I doubt that air was still in there, but i will try couple more times? And if I fail, i need to replace the thermostat.

Would that be your best guess?


Take care, and thank you very much for the support!

Damien!

[JR]

OK I'll answer your questions one at a time.

Your coolant really needs to be a 1/2 mix of good grade coolant and water, it does make a difference. If you do not have coolant that's available already premixed then simply buy some good coolant and preferable distilled water and mix it yourself. The whole system uses less than 2 quarts so a gallon jug will be fine and where you live I'm sure you use liter instead.

The little plastic tank needs to be empty and just disconnect the hose on it where it hooks up at the radiator cap and if need be use some copressed air to blow it out.

Now since you have used nothing but water I'm sure your system is clean so again take out the drain screw and drain it dry. Again if you have any compressed air you can put a hose in the radiator fill nozzle and add air to blow it all out.

Now I copied and pasted tj burp process and answering another question, yes it's important to let the scooter cool completely. The cooling process allows air to do what it always does rise to the top in this case the top of the radiator fill nozzle where the cap is. Everytime you pull the radiator cap off it you have to add coolant then that means some more air was in the system.

Another thing is to be ready with all of your coolant and caps or organzied. As in the burping instructions take the radiator cap off fill the radiator ful until it will hold no more coolant.

Have the reservoir empty and a funnel in it ready to put coolant in.
Start the scooter leave the radiator and reservoir tank caps off.
As the scooter starts to circulate the coolant most of the time it will go down or recede especially after the thermostat warms up and opens, IMMEDIATELY refill the radiator, place cap on tight.
As soon as you put the cap on the radiator fill the resevoir tank about 1/2 to 3/4 full put cap on and then let her warm up, you can even take a quick spin around the block, watch the temp gage closely and if it starts getting hot shut her down, the fan may or may not come on don't worry about it.

Now be patient and let her as I say get bone cold, remove the radiator cap, check for needed coolant, fill if needed and do it all again.

If you have no other issues like a bad thermostat or failed water pump this will get the air out and make her settle down.

Also I suspect your reservoir tank was too full and it was forcing water out of the top is why you saww water leaking? Other than that if it continues to leak you've got to find out where.










Now here's how I (burp) or get the air out of the system after replacing the coolant;

Now to get started;

(1) Put scooter on center stand and remove carb/radiator plastic cover under the seat.
(2) Place catch pan under the drain bolt location, remove allen head bolt, then remove radiator cap. [DO NOT LOSE COPPER WASHER ON BOLT]
(3) After coolant is drained take water hose and flush radiator well with clean running water, can even do it two or three times. If you have an air compressor you can even blow out all water completely
(4) Replace allen head drain bolt with the copper washer , a little silicone gasket maker is good to use too, secure tightly.
(5) Fill radiator completely with coolant, a long funnel is nice and doesn't make a mess. [USE ONLY COOLANT FREE OF NITRATES, BORATES, SILICATES & SPECIFIED FOR ALUMINUM BLOCK ENGINES] One can mix their own coolant on a 50/50 ratio but it is a lot easier to use a 50/50 premix (I use Prestone)
(6) Start scooter and let run until thermostat opens and you see coolant start to circulate (this only takes a few minutes) Re-fill until full as the coolant will generally go down, immediately put on radiator cap securely after re-filling
(7) Fill radiator plastic reservoir tank to about 3/4 full with same coolant after putting on the radiator cap
(8) Let idle until the temp gauge comes up to about the 1/2 way mark and then shut off scooter (the fan may or may not come on, doesn't matter)
(9) Go watch TV, read a book, but let scooter sit until it's bone cold.
(10) Remove radiator cap and re-fill with coolant, start engine, let circulate, fill again if needed, put radiator cap back on.
(11) Fill plastic reservoir tank again to about 3/4 full, put on rubber cap and watch temp gauge and see if fan cycles on and off.
(12) DONE!

If for some reason it seems to want to get warm and fan not cycle on and off then repeat steps number 9,10 and 11 again.
You can even run the scooter around the block and see if the fan comes on and off and how the temp gauge reads.

This has always worked for me first time and every time.

JR