confusing electricals again! By erinsdad (Read 696 times)

[erinsdad]

Hey everyone! I finally put the scoot inside. BTW, when I say inside, I really mean in the Living Room. I'm trying to find out what's going on with my scooter electricals. First, my headlight is on when the power switch is in the off position. I'm told it should be the other way around. I got a new ignition switch & everything still ran like it did before, light on/ key off. Now the next thing is also electrical, when I was installing the new ignition switch, I noticed an odd little bundle of wires. Colors are- orange-Grey- Grey, then solid green with green/ yellow then black. Inside the tube where you can't see it is a yellow wire that was cut off even with the little tube. I've read you guys talking about a yellow wire to the tail light assembly. However, the present wiring system Has a yellow wire back there already. Now today, all the power just went away. It came back a couple hours later, but it sure makes it hard to diagnose things!!!
Any ideas???

[alleyoop]

How about some pictures so we can see what is what maybe we can tell what they are for.

Also what works and what does not work when you turn the KEY ON? Do you have SPARK. lights instrument panel light, horn,
turnsignals, when you squeeze the brakes do you have stoplights, running lights, gauges work or not etc..
Alleyoop

[alleyoop]

I will email JR he is the Electrical GURU I can get around pretty good but I am a Carb, Motor, CVT and Tranny guy. He knows wiring and the colors.
Alleyoop

[JR]

You are confusing on your color scheme? On multicolored wires list them as yellow/black etc. If it is a one color wire then of course list is as a single wire.

Now here is the diagram of the Tank DE150 and even though it is a 150 Tank generally wired all their models the same with the exception of water cooled versions.

.thescooterprofessor.proboards.com/thread/1428/tank-wiring-diagrams" rel="nofollow" target="_blank">.thescooterprofessor.proboards.com/thread/1428/tank-wiring-diagrams

Now if you notice on the switch listed on this diagram it shows that there are two yellow wires feeding the system of lights. What that means is they run one yellow wire which BTW ties into the R/R yellow feed from the stator and then they will put a little jumper wire in the switch itself which is the "other" yellow wire you see on the diagram. Now they are notorious for using any color they find for this jumper wire even green.

But what this means is with the switch wired this way is they allow you to switch the headlight off and have taillights only because they "both" feed off of the yellow wire. Even more confusing is the fact of they may run yellow to the switch, use a other color wire for the yellow to the second part of the switch going to the tail lights and then use brown to the tail lights from there? Brown is the universal color for tail lighting in nearly every thing moving even a automobile.

Now what's even more confusing is your colors you mentioned? Is this the light switch wiring or key switch wiring? If your scooter is wired like this 150 and I suspect it is then the key switch wiring has nothing to do with the lights, they are independent of each other. The only way they tie into together is if someone has changed the sequence. The key switch has two functions, turn on power to the accessories, horn, brake lights, etc. and to kill the engine. In some cases the head/tail lights are on the key switch battery power but only on modified to DC systems and 50cc scooters are all AC lights, not DC again unless someone changed your scooter. If this is the case then more than likely it'll never hold a battery charge.

I need to know this:

Are the colors you mentioned key switch wires of head light wires?
Has someone (previous owner) modified the wiring?
What has always been the headlight pattern, does it come on when just turning on the key or only with the engine running?
If the wires you mentioned are key switch wires then I need true colors of the headlight switch if it has one or the colors to the dimmer switch.

Alley mentioned pictures, it is the best way to go.

JR

Edit:

Inside the tube where you can't see it is a yellow wire that was cut off even with the little tube.

This tells me the scooter wiring has been compromised, I didn't see this in the original quote you made. I'm betting they tied the wire from the light switch into the ignition. Time to open her up and start tracing wires. If you don't have a multimeter go to Wal mart and get a cheapo. When running this yellow wire that is cut off should have voltage.

 

[erinsdad]

Hey, I'm back!! OK you wanted some pics, so here they are.
This one is the harness from the left brake handle assembly. This is where that mysterious yellow wire was hiding. I chased it & came up with this chewed up end on the front & it went all the way to the back to the taillights. the last 6 inches or so was repaired with black, black, green. The next one is the END of that same yellow wire I found up front. The last is the harness for the ignition switch. I got the new one because the things that were supposed to be switched were not & I just kept losing stuff for periods of time. All 4 wires were kinda tore up. Things are starting to come back, now I want to clean up the wires, and maybe rearrange them so stuff isn't so hard to find!!

Attachments:

[JR]

1st photo:

Big plug:

green = ground

dark green = horn

orange = left blinker

light blue = left blinker

black = 12vdc with key on

yellow wire that is loose = headlight feed wire

Two plug:

Yellow = possible feed to dimmer switch or to low beam head light

Blue = high beam head light

2nd photo:  Puzzling? Question? Photo appears to show on one side green, black. black, you said they had been repaired?

Now the other side of the plug appears to be green, yellow, green/yellow?

If this is the case then green = ground

yellow = tail light feed

green/yellow = brake lights & starter relay, (remember the scooter must have a brake handle pressed to start)

Third photo:

Red = 12Vdc from battery

Green = ground

Black/white = engine kill wire

Black = 12Vdc with key switch on

Now since they did repairs on the plug with black wires you need to confirm they matched the wire correctly, simple way to do it for the brake lights, turn the key on and press either brake handle, make sure they are bright and that they didn't mix it up and put it on the dim side which would be the tail lights.

Next if the headlight/s come on with just the key on you need to start tracing wires, the yellow that is loose is the head light voltage feed wire from the stator, start the scooter if you can and check it for voltage with it running. They have spliced into the black wire in that harness somewhere and wired the headlight/s to it.

JR

[alleyoop]

What did I tell Erinsdad, JR is a WIRE himself did I not say he knows the wire colors
Alleyoop