issues - swapped alarmed harness for non alarmed By godfeast (Read 1,617 times)

[godfeast]

My fuse keeps blowing on my scooter.

A few days of testing, and I cant seem to find the short.

The best thing I have found after rewiring the harness at the ignition, rectifier, headlights, and tailights, is that when the starter relay wires ( the plug, not the power to the relay or going to the starter) are plugged in, the fuse at the battery blows.

Does this limit me to a bad relay or starter or is it possible that something else is in line with this wiring?

I am horrible at reading schematics and trying to do my best, but its mostly guess work.

Any helpful ideas on what else I can test with a meter or otherwise to find the culprit?

[godfeast]

update:

switched out relay.

Found that fuse blows when either:

1. attempting to start the bike

2. the cut off switch is switched to the right with ignition on

[tvnacman]

you crossed the ground with power , your kill switch is a ground , if your ignition switch is 4 wire it switches power on and ground off in the run position . Then is the off position turns power off and closes ground .

John

[godfeast]

so would that indicate a bad switch or bad wiring to the switch do you think?

The ignition is less than a few months old as well...

[tvnacman]

If the switch has 4 wires/4connections ohm it out . two termnals will be zero ohms in the off position the other two will be "OL" when you switch the run position the readings will reverse . with the switch in the off position the two termnals with zero ohms is your ground and the other termnals are for switched power .

John

[JR]

What he's saying in simpler terms Godfeast is the key switch is a two way switch as in normally open (NO) and normally closed (NC).

With the key off you disconnect the power to the scooter accessories, horn, turn signals, brakes, etc.

At the same time you close the other side of the switch and gropund out the CDI to kill the engine.

Wire colors to the key switch are as follows;

red = 12VDc from battery
black = 12VDC output to accessories
green = ground
black/white = engine kill wire

Also as he said when you push the start button you are supplying ground to the stater relay.

A short that is blowing the fuse will be on the black wire from the key switch fedding a accessory and if it happens when you try to start the scooter then it is in the brake light circuit more than likely the yellow/green wire that goes to the brake lights and at the same time the starter relay.

Check your brake/tail light bulb sockets and all of the brake/tail light connections at the back of the scooter for a wire that is grounded out.

JR

[godfeast]

Thanks guys. I took electronics in high school, so I follow a bit, but it seems I def need to learn more.

I appreciate both the help and the clarification.

I have to work around work, so cant get to it asap, but I've decided to pull the harness off and lay it out to look for problems; going to strip it, then solder connections that look bad and retape before troubleshooting further.

This has saved me time in the past, and I hope it will again.

[godfeast]

I finally got down to my storage unit today and located a totally clean harness I had off a wrecked scooter with low miles I bought a while back.

The only thing different from the one I have in the scooter now (besides wire fraying, lol) is that it was setup to accept a scooter alarm of some sort.

I now have to bypass this somehow or cut it out of the harness to get this work - anyone have an idea of what I need to do?

I'd like to save time unwrapped both and then trying to make them identical if I can just short or open a couple wires and be done with it.

I read in another forum that it just requires jumpering the black+white and brown+white wires at the alarm harness.

Is that so? And if so, do I still leave the bullet connection on the black+white wire connecting to the ignition?

[alleyoop]

for the Alarm..check the wire colors if you have a brown/white and a black/white wire in the harness plug join them together with another wire. Or it may have grey and pinkish color wire connect those.
alleyoop

[JR]

That is correct, jump the black/white to the brown/white, this will keep the kill circuit complete so when you turn the key off or hit the emergency kill switch the scooter will quit running.

JR

[godfeast]

I do have those lines coming from the alarm connector, however, the black+white has a bullet connector going to the ignition.

Should I leave that connected and then short the wire at the alarm plug with a jumper?

[JR]

Yep exactly.

JR

[godfeast]

hmm... I looked at the harness closely and Im confused now.

The plug thhat would go to the non-existent alarm has a brown+white wire that had a bullet connector and goes to nothing else - I cut off the end before I realized this seemed wrong.

The other bullet connector goes from the wiring at the alarm plug (not actually into the plug) to the black+white wire coming from the ignition.

Connecting the brown+white wire will actually do nothing because it plugs into nothing.

Is this already setup to work without an alarm then by virtue of the black+white alarm wire already going to the ignition plug?

Ill post pics here of what Im talking about.

[godfeast]

I have to do my projects on something other than a holiday weekend, lol.

I still have the harness out, so rather than cut it open and lay it beside my other harness, is there perhaps a certain wire at the cdi or something that I can simply check at the alarm plug with a multimeter to find the right wires to earth or jump if its not already setup correctly?

I have no idea if the owner of the old trashed scooter had an alarm installed or not since I bought the frame with the front of the bike mostly pulled already.

[godfeast]

After having used the multitester on it, the black+white wire from the alarm plug that is connected to the ignition seems to go to only two other places, one of which is the kill line on the cdi and the other is up in the instrument panel (unsure of what it leads to from there yet).

I tested the old harness as well, and that seems to be the only two spots on it that the black+white wire leads to, and after having tested both harnesses, it seems that with the bullet connector in place from alarm plug to ignition, that they are both wired identically and therefore logically should work.

Putting it in bike tomorrow morning.