ok i will try to trace back some things is there a way to start from scratch with all new wiring as i have heaps of it so many wires in this harness
Another question should I be getting power from pigtail red/yellow from starter solenoid or green/yellow either ? As I'm using a test light now
Actually that's not a bad idea and you can just pull this harness apart and we can use the wires that apply with the plugs we want too.
We know the key switch plug had some things that were right, the fused red wire had voltage like it should, the black wire was hot when we turned the key on. I'm sure the green and the black/white in the plug are usable too.
So if you need too pull the harness apart and start singling out the color of wires we need. After we get it going we can tape/bundle them back up neatly.
So now we know we want the plug that plugs into the key switch with the following wires
Red- which needs to be the fused wire going to the positive terminal of the battery
Green-and I mean solid green this wire needs to go to the negative terminal of the battery.
Black-from the key switch, we will use this wire to feed our brake light switches
Black/white- we will later use this wire to go to the CDI to kill the engine when turning the key off, WE ARE NOT worried about this wire at present.
We will need the other following wires:
Red/yellow-which we will use to feed the negative side of the starter relay
Green/yellow-which we will use to feed the positive side of the starter relay.
Now there are other wires that we will use to other things but at this moment we are not worried about them, we are trying to get the start circuit working.
The starting circuit is actually simple, we are putting 12Vdc to the solenoid relay through the red wire from the battery through the black wire out of the key switch to the brake switch which sends the voltage out on the green/yellow wire to the solenoid relay. Now for this to work we also have to have good brake switches and of course a good key switch.
So lets look at the simple diagram again if you click on the small thumbnail of this diagram it enlarges to a better view;
In the diagram we see the solenoid relay with the main terminals hooked up, one wire comes from the positive side of the battery, the other terminal goes to the starter, of course the battery has the negative side and it's ground, enough said.
Now we have the small wire pigtail, one wire green/yellow the other wire red/yellow.
The red/yellow goes to where it says start, simply put this is the start button and in our case we will hook this wire to the BROWN wire going to the start button. We then need to run it to the red/yellow wire pigtail on the starter solenoid. The other side of the diagram on the start button shows the GROUND symbol. In this case we want to use a solid GREEN wire in the harness AND we want to make SURE it ties into the same green wire that we are going to run from the negative side of the battery to the GREEN on the key switch. We will hook this green wire to the BLUE on the start button. This will complete the START Button side of the circuit.
I got a little ahead of myself here.
Make SURE you run the RED fused wire to the red on the key switch.
Make sure you run a solid GREEN wire from the negative side of the battery to the GREEN on the key switch. After you know that you have these two wires rune we can test the key switch to make sure it's A-ok.
Now we need to use the BLACK wire off of the key switch. We are going to run the BLACK to the BLACK on the brake light switch. If you have two brake switches then split it and run a black to each switch from the BLACK on the key switch, that's up to you if you want to use both. It makes it where you can start the engine by using either one of the brakes, again this is a safety feature.
Now take a GREEN/YELLOW and tie it in to the green/yellow coming off of the brake switche/s, again if you want to use either brake then split the wire and tie then into a single wire going to the other solenoid relay pigtail wire which is also green/yellow. This is what the diagram shows above.
Now if you hook this up like I said, the key switch, start button and brake switches are all good then you should be able to take your test light and do this.
Plug the test light into the pigtail you just ran that you are going to hook the solenoid relay up to one wire on red/yellow, one wire on green/yellow.
Turn the key on
Press and hold a brake handle down which activates the brake switch
Hit the start button.
If all is correct and good the test light will light up. It then can be plugged into the solenoid relay for use.
JR
