butchered wiring harness By rangerdaver91 (Read 17,607 times)

[justbuggin2]

ok you need to check the intake for leaks and i would say that there are some problems with the carb still i would pull the carb apart and find some fine wire and go though all the tiny hole and passages in the carb inspect the diaphram and make sure it does not have any pin holes

[JR]

Jun 27, 2012 7:46:57 GMT -6 rangerdaver91 said:

Alright JR, you are the man. I wired it up like you said and it starts and runs. It ain't ride-able, it has a serious bog when I try to give it gas. I have taken the carb apart and cleaned it . it runs the best with the mixture screw almost all the way in, but still can only take a little throttle before it goes to bogging. We have tried it from seated to backed all the way out till it started dieing on us ,and still can't get it to smooth out and take throttle. Any ideas what to look at next ? I checked the auto choke and it does push the plunger and needle out after being hooked to 12 volts for a few minutes. Damn the bad luck. so once again I am begging help. And I want to thank you very kindly for all the time , effort and help you have been. I was completely lost without your guidance. Maybe with your help I can fix this problem also.

Man am I glad she fired! I was going by wiring diagrams I looked at and hoped that would do the trick!

Did you pay close attention to the jets when you cleaned the carb and made absolutely sure the tiny holes were all open?

Old Alley will be online shortly I'm sure and he is the bogging man, knows all the tricks.

But let me think on it too. We're getting closer!

JR

[alleyoop]

Hi Justbuggin2,
Since it runs the best with the Fuel Ratio Screw turned almost all the way in, it means it is getting to much fuel.

Q1.
Have you checked the Air Filter it may be all dirty and clogged.
Q2.
Did you ever change the Jets in the Carb

Check the Vacuum Line from the Petcock or Fuel Pump pull it off and see if it is DRY. It could be leaking and allowing fuel to flow freely through the Vacuum line.

Also take the Fuel Ratio screw out and make sure the point is still there sometimes people will turn the screw all the way in and tighten to tight and flatten the point on it.

One more thing when you cleaned the Carb did you take the jets out and the defusers out as well and did the Needle Guide come out. If you put the needle guide back in backwards it will suck fuel from there when it shouldn't.
Alleyoop

Here is what I am talking about when I say the needle guide:

[rangerdaver91]

JR, yes I checked all the holes and they are open.

alleyoop, Q1 the scooter does not have an air filter, the people that had it are looking for the air box and other missing items for the scooter.
Q2 I have not changed the jets, they are the original jets.
Vacuum line is new and dry. The fuel mixture screw is flat on the tip but appears to be that way from the factory. It's tapered with a flat tip. I tried to take a pic but my camera just wont take a close up of something that small. The needle guide is installed correctly. And yes I took the jets out when I cleaned the carb.
The carb is made in Italy. It is a Dellorto, it has PHVA 175 embossed on it and 1389-D7 stamped on it.

[rangerdaver91]

This is the fuel/air mixture screw

[JR]

Didn't you say no air filter? Hard to adjust and get a carb to act right with an fully open air intake. If you can't get the OEM filter setup you'll need to put a unifilter on it.

JR

[rangerdaver91]

Thx JR, I will get one today. I got to looking at the carb and found that the needle and slide were assembled incorrectly, I fixed that problem and had a little better luck. Getting closer all the time. One day soon I will have her purring for me lol.

[lazerorca]

I wish i could contribute a little something to this thread besides that JR knows his stuff. he helped me sort through a quagmire of wires on a generic wiring harness I had. the job done before was a hack job on it and he helped me get through the maze of crap.

alleyoop also helped me out with advice I needed for replacing a crank seal. These guys are very helpful and great at explaining things if you have pictures.

[rangerdaver91]

Yes, they are great guys, very knowledgeable , friendly and helpful. And very much appreciated.

[rangerdaver91]

JR, This is the wire that we left unhooked. I know earlier that you said the red/white wire could be taped off, but did you mean white/red ? because thats what was left and looks like in the pic that it maybe should be hooked up some where. Did we maybe leave the wrong wire from the stator unhooked ? I have been thru the carb multiple times, rejetted to an 84, tried every needle clip position and tried every where from bottomed out to backed out till it would not run with the mixture screw. I have made major improvements. It starts with the touch of the button, idles great and can now take some throttle but still won't take it and go. Could this be a timing issue involving this white/red wire that is not connected ?

[JR]

OK got a question? Yes I did mean white/red and this wire with the female bullet connector is it the same wire as the one on the left that is soldiered on to what appears to be the pick up coil?

If so I don't know how it could be running at all without this wire hooked up?

Ok lets try this because again we are trying to make a 5 wire CDI work where a 6-wire one did before?

Unhook the green/whitewire from the stator that is hooked up to the red/white on the CDI and hook red/white on the CDI to the white/red that is loose now and see if this makles a difference?

In the mean time I'm going to see again if I can find a two stroke 6 wire CDI?

JR

[alleyoop]

Check the wire that JR said I labled it on your picture. IF that one loose wire is the one coming off the Pick-Up COil that wire goes on the CDI which tells the CDI when to release the Voltage to the COIL to fire the Plug.
Alleyoop

[rangerdaver91]

Yes the white/red wire is the same I took it apart and visually checked it to be certain. Here are some pics of the stator and the plug in end of the wires coming out of the motor from the stator. You can see the 6 wires and where they are connected at the stator, the blk ground is screwed to the plate that holds the stator in. There is a place where the red arrow is pointing that has a bare spot where the plastic has rubbed the inside of the magneto and metal is showing. Don't know if this is a problem or not. I tried the wire change that you suggested and there was no fire.

[justbuggin2]

that wire is from your pick up coil for the ingition if you have no fire with it hookup then you pick up is bad sounds like you have been running off of the coil that is suppose to charge the coil and the timimg of it will be off

[rangerdaver91]

You are talking about the white/red wire ? When I hook it as JR said above I have no fire. When it is hooked up as he had me do at first it starts and idles fine, runs sort of ok when I first start giving it gas but craps out when I try to give it more than just a little throttle. The more throttle the more she spits, sputters and bogs. I no longer believe it to be the carb, But now am thinking it is something to do with the timing (stator hook up). Where is this white/red wire supposed to hook into ? It has to get a signal from somewhere. I think it controls the timing advance. The problem is the stator has 6 wires and the new CDI only has 5 wires. Is the black plastic piece on the outside of the magneto(flywheel) with the white/red wire the pick up that controls the timing? I am not sure of the name of all the components , I know what the magneto and stator are but like the black plastic piece on the inside of the magneto with the black/red wire and the white/green is called. I know we are right on the edge of getting it, there has to be just some little something that's not right.