Post by JR on Mar 5, 2012 18:42:39 GMT -6
Ok what I would like to do is to take this one step at a time. I'm not worried about the little wires and such or what I call the accessory wires, they are easy'
What I want to do is the start with ther ignition circuit as far as making the scooter turn over. I'm not conmcerned about starting it now but rather being able to turn the key on, press the brake handle, hit the start button and the starter engage and turn the engine over.
So with that said let's start with picture number 1. If this is the plug that would go to your ignition then the red of course goes to the red on your ignition switch. This red wire should be the red wire shown in picture number 9 hooked up to the battery and IS FUSED. So you must make sure this is that wire.
The green is ground and we will have to figure out if it hooks to one or both of the greens on the ignition key switch.
The black will be the hot 12Vdc wire off of the key switch. Now does this black on this plug with the green and red wire go to another plug and end or does it run to somewhere else? If it just goes to another dead end plug then great we are OK.
So hook the red from this 3-wire plug to the red on the key switch if it is the fused red wire hooked to the battery and hook up the black wire on this plug to the black wire on the key switch.
Save the green wire until we test the key switch.
Now the single red/white wire with the single bullet connector on it. We need to know if it indeed goes to the CDI? Got to trace this wire out. Here is the pin out of the typicaL GY-6 cdi;
In your CDI picture on the two plug it looks like you have a red/white and red/black. If this is the single red/white wire at the end with the 3-wire plug then it will hook to the black/white on your key ignition.
Now on that same two plug I mentioned the red/black and you need to trace this wire out and see if it hooks to the black/red from your stator wire harness? In picture number 4 it appears to do just that?
Now on the 3 plug on the CDI it's hard to see but it appears you have a green/red, a blue/yellow and a green.
Normally the coil wire is yellow/black but in picture number 6 of your coil it has this same green/red and of course a green (ground)? If this is the same wire from the CDI to the coil then it is correct.
Now the blue/yellow appears to hook into a red/white on the stator wiring in picture number 4? if so then this is the pick up coil wire and it is correct.
Of course the last wire is green and it is a ground and remember all of these greens generally tie together in the harness at different points and in picture number 8 you have a green wire with a brass eyelet connector on it, it hooks to the frame and the negative battery cable hooks up there too. I also want to mention YOU MUST have a ground wire hooked up to the engine itself. Most of the time a jumper wire from the fan cover bolt on the oil dip side has this wire hooked to it and it runs to the frame where the negative battery cable hooks up.
Now in that same picture number 8 where you are holding that green wire is indeed the plug that plugs into your regulator (R/R)
The red wire off that plug goes to the battery positive side for charging. The white and yellow wires go to your stator plug, the green one in picture number 4. Of course hook white to white, yellow to yellow.
The green wire on that same plug must be grounded, hook it up to the negative battery cable where it bolts up to the frame.
On the green plug from the stator on the engine you must hook up the green wire on that plug to ground again hook it up on the frame where the negative battery cable bolts on.
In picture number 7 the large red/white wire looks like a wire that wouild come from the solenoid relay and hook up to starter?
Now on the starter relay you have two small wires a yellow/red and a yellow/green. The yellow/red goes all the way to the start button.
The yellow/green goes all the way up to the brake light wires where they split. Both the right and left brake light wire (yellow/green) tie into this wire going back to the starter relay.
Now here is where I need some help and another picture. You mentioned on the emergency kill switch and the start button these wire colors I believe? Yellow/red, black/white, green and black.
The black is not normal but sometimes they will use a black wire to jump from a green ground wire to another place. The negative cable on the battery going to the frame is lots of times black.
But up front where you key switch is and things like the horns and brakes are black is ALWAYS the 12Vdc HOT WIRE. So I need to know again the color wires on the emergency kill switch by itself..... and the start button by itself. We know for sure one wire to the start button is yellow/red. Now if there is a black wire to the emergency kill switch I need to know exactly where it goes to. It will not be a hot wire. There is no voltage to the emergency kill switch or start button PERIOD!
When you press the strat button you are sending the ground part of thew circuit to the starter realy through the yellow/red wire. The posisitve side of the starter realy is recieved through the yellow/green from the brakes when pressed.
We will have a yellow/red to the start button and another wire, need to know what color and where it goes? I'm betting it gfoes to one side of the emergency kill switch where you should also have a green(ground) and the black/white CDI wire Again a clear picture and what goes where and what colors. This is important as again I want to get the starting function out of the way. You need to make sure your battery is charged also.
Now remember the yellow/green hooks up to both brake handle yellow/greens? OK also both blacks on the brake handles need to hook to the black wire on the key ignition switch. This is where we get out power for starting.
Also I need you to take a good clear picture of you volt meter with the leads and the face so I can tell you how to set the meter for ohm testing. We have got to do a test on the key switch and it's easy once you know how.
Alright this is a lot to check and get those pictures and start hooking up the things I've said to and we will figure out the stater/emergency kill switch wires and functions and hopefully we will get this scooter to run over and go from there.
JR
What I want to do is the start with ther ignition circuit as far as making the scooter turn over. I'm not conmcerned about starting it now but rather being able to turn the key on, press the brake handle, hit the start button and the starter engage and turn the engine over.
So with that said let's start with picture number 1. If this is the plug that would go to your ignition then the red of course goes to the red on your ignition switch. This red wire should be the red wire shown in picture number 9 hooked up to the battery and IS FUSED. So you must make sure this is that wire.
The green is ground and we will have to figure out if it hooks to one or both of the greens on the ignition key switch.
The black will be the hot 12Vdc wire off of the key switch. Now does this black on this plug with the green and red wire go to another plug and end or does it run to somewhere else? If it just goes to another dead end plug then great we are OK.
So hook the red from this 3-wire plug to the red on the key switch if it is the fused red wire hooked to the battery and hook up the black wire on this plug to the black wire on the key switch.
Save the green wire until we test the key switch.
Now the single red/white wire with the single bullet connector on it. We need to know if it indeed goes to the CDI? Got to trace this wire out. Here is the pin out of the typicaL GY-6 cdi;
In your CDI picture on the two plug it looks like you have a red/white and red/black. If this is the single red/white wire at the end with the 3-wire plug then it will hook to the black/white on your key ignition.
Now on that same two plug I mentioned the red/black and you need to trace this wire out and see if it hooks to the black/red from your stator wire harness? In picture number 4 it appears to do just that?
Now on the 3 plug on the CDI it's hard to see but it appears you have a green/red, a blue/yellow and a green.
Normally the coil wire is yellow/black but in picture number 6 of your coil it has this same green/red and of course a green (ground)? If this is the same wire from the CDI to the coil then it is correct.
Now the blue/yellow appears to hook into a red/white on the stator wiring in picture number 4? if so then this is the pick up coil wire and it is correct.
Of course the last wire is green and it is a ground and remember all of these greens generally tie together in the harness at different points and in picture number 8 you have a green wire with a brass eyelet connector on it, it hooks to the frame and the negative battery cable hooks up there too. I also want to mention YOU MUST have a ground wire hooked up to the engine itself. Most of the time a jumper wire from the fan cover bolt on the oil dip side has this wire hooked to it and it runs to the frame where the negative battery cable hooks up.
Now in that same picture number 8 where you are holding that green wire is indeed the plug that plugs into your regulator (R/R)
The red wire off that plug goes to the battery positive side for charging. The white and yellow wires go to your stator plug, the green one in picture number 4. Of course hook white to white, yellow to yellow.
The green wire on that same plug must be grounded, hook it up to the negative battery cable where it bolts up to the frame.
On the green plug from the stator on the engine you must hook up the green wire on that plug to ground again hook it up on the frame where the negative battery cable bolts on.
In picture number 7 the large red/white wire looks like a wire that wouild come from the solenoid relay and hook up to starter?
Now on the starter relay you have two small wires a yellow/red and a yellow/green. The yellow/red goes all the way to the start button.
The yellow/green goes all the way up to the brake light wires where they split. Both the right and left brake light wire (yellow/green) tie into this wire going back to the starter relay.
Now here is where I need some help and another picture. You mentioned on the emergency kill switch and the start button these wire colors I believe? Yellow/red, black/white, green and black.
The black is not normal but sometimes they will use a black wire to jump from a green ground wire to another place. The negative cable on the battery going to the frame is lots of times black.
But up front where you key switch is and things like the horns and brakes are black is ALWAYS the 12Vdc HOT WIRE. So I need to know again the color wires on the emergency kill switch by itself..... and the start button by itself. We know for sure one wire to the start button is yellow/red. Now if there is a black wire to the emergency kill switch I need to know exactly where it goes to. It will not be a hot wire. There is no voltage to the emergency kill switch or start button PERIOD!
When you press the strat button you are sending the ground part of thew circuit to the starter realy through the yellow/red wire. The posisitve side of the starter realy is recieved through the yellow/green from the brakes when pressed.
We will have a yellow/red to the start button and another wire, need to know what color and where it goes? I'm betting it gfoes to one side of the emergency kill switch where you should also have a green(ground) and the black/white CDI wire Again a clear picture and what goes where and what colors. This is important as again I want to get the starting function out of the way. You need to make sure your battery is charged also.
Now remember the yellow/green hooks up to both brake handle yellow/greens? OK also both blacks on the brake handles need to hook to the black wire on the key ignition switch. This is where we get out power for starting.
Also I need you to take a good clear picture of you volt meter with the leads and the face so I can tell you how to set the meter for ohm testing. We have got to do a test on the key switch and it's easy once you know how.
Alright this is a lot to check and get those pictures and start hooking up the things I've said to and we will figure out the stater/emergency kill switch wires and functions and hopefully we will get this scooter to run over and go from there.
JR
..BAD TO THE BONE..
