wiring and starting By o0ohakko0o (Read 14,705 times)

[JR]

OK you're making it easier so let's take on thing at a time. The Blue/white and the red/black on the wires coming from the engine go to the same colors on the CDI.

Red/black = AC feed to the CDI which gives it power
Blue/white = pulse coil which tells the CDI when to fire.

The black/yellow on the CDI goes to the Black/yellow on the coil.
The GREEN on the CDI goes to GROUND = Green
The GREEN on the coil goes to GROUND = Green.

Remember I told you the harness will have several GREEN wires which is the GROUND to several things.

BTW there is a GREEN wire on your key switch too, make SURE it is tied to GROUND = Green also.

Lastly there is the black/white = engine kill wire and that wire goes all the way to the key switch black/white.

Now I'm going to explain how the key switch and the four wires on it work so you can understand this. Your key switch is a two way switch and that means it is a what electricians call a normally open and normally closed switch at the same time.

When you turn the key on you close the contacts of the RED to BLACK which means you send 12Vdc power from the RED wire to the BLACK wire.

At the same time when you turn the key on you OPEN the contacts to the GREEN and BLACK/WHITE wires. You want this open for the engine to run why? When you turn the key off you open the contacts from the RED to BLACK thus cutting off the 12Vdc power but at the same time you then CLOSE the contacts to the GREEN and BLACK/WHITE wires which sends ground to the CDI. With CDI grounded out the sparkplug can't fire thus you KILL the engine.

Now I'm going to give you another task of wiring to complete the engine kill circuit. Remember the other wires on the handle bar switch assembly that we are going to wire up? We currently are using the blue and brown for our start button.

Now we are going to use two more wires. I want you to hook up the solid GREEN wire to GROUND, the same GREEN you use for GROUND every where else the same GREEN you will hook up to the key switch.

I also want you to hook up the BLACK/White in the handlebar switch assembly to the BLACK/WHITE on the key switch.

In other words tie the BLACK/WHITE to the key switch and handlebar switch together and then run a single BLACK/WHITE wire to the BLACK/WHITE on the CDI.

When you want to start the engine it's important to ALWAYS make sure the engine kill switch on the handlebar switch assembly is in the RUN position because it also grounds out the CDI which kills the engine. Many a person has said the engine will turn over but not start and then discover they have the kill switch on the handle bar in the KILL position! LOL

When you get this done then if everything is in working order we then can test to see if the sparkplug will fire.

Don't worry about the other wires coming from the engine at this point, we will get to them next.

JR

[JR]

When you get all this done I'm going to want you to screw the spark plug out and we'll test to see if we have a good spark, here are some videos on how to test for a spark:

thescooterprofessor.proboards.com/thread/4167/electrical-check-spark-tester-method

BTW the other wires coming from the engine temporarily put some tape on them and don't let them touch anything while we are testing for spark and don't let them touch each other, we don't want to burn up the stator.

JR

[o0ohakko0o]

This may sound stupid but you say green to ground your saying green to chassi or tape the end of the green wire

[JR]

In the harness on the black (negative) battery cable is also attached a small solid GREEN wire, it's the same GREEN wire that you used on the BLUE wire to the start button, which is GROUND and that wire is all through the harness.

So when I say hook up the GREEN wire or GROUND wire then make sure you use the same GREEN wire that is on the negative post of the battery.

You have a GROUND wire = GREEN that goes to several things like I mentioned above, key switch, CDI, etc and just make sure that it is the same wire that goes to the negative side of the battery and you'll be fine.

[JR]

Ok I've been thinking about the handle bar switch assembly now don't let this interfere with the things I want you to wire in my previous posts, do everything just as I told you to do. This is for future things we are going to do. I'm a little puzzled about the wires and colors on a couple of things, here is the switch assembly picture you took:




Now we have got the start button done correctly and the blue and brown wire are correctly wired and finished.

I told you in the last instructions to wire the BLACK/WHITE with the BLACK/White on the key switch and then run them down a single BLACK/WHITE wire to the BLACK/WHITE on the CDI. I also said hook the GREEN in this switch assembly to a GREEN wire that is GROUND which is the solid GREEN wire on the black negative battery cable and I still want you to do these wires as directed.

This handle bar switch assembly has 3 switches, Start button, headlight on/off, and engine kill switch or what some call engine run or engine off switch. The part of the switch that is engine run or off looks like this:

i.ebayimg.com/images/i/350642747622-0-1/s-l1000.jpg

Now I absolutely have no doubt that one of the wires that runs to this switch is BLACK/WHITE but I need you to verify the other wire color on that particular switch. In your picture I cannot see this. Let me know so I can make sure I am wiring it correctly. I'm not worried about the start button wires or the headlight wires at this point.

JR

[o0ohakko0o]

On that particular switch there are 2 wires
Black/White and Solid Yellow


Ok JR i have a photo of the Handle Bar switch that have 6 of these color wires female plug (apart from those 2 wires we used Blue , Brown .. you will see in photo )
Solid Black ,Solid Yellow , Black/White , Solid Green , Solid Red , Solid White.


Then the male plug that connects into female plug has 6 wires
Black/White , Solid Green , Solid Blue , Solid Black , Solid White , Solid Brown
but when the MALE plug is connected into FEMALE the wires don't match as you may see in photo

Solid Green from male plug is connecting to Black/White
Blue from male plug is connecting to Solid Green
Solid Brown from male plug is connecting to Solid Red
Black/White from male plug is connecting to Solid Yellow
Solid Black from male plug is connecting to Solid Black
Solid White from male plug is connecting to Solid White

[JR]

OK you got the info I wanted and we'll match some wires up like I want to. Good Job! Now I DO NOT want you to change the wires at all on the FEMALE plug that goes to the handle bar switch assembly.

But we WILL change some of the wires on the male plug you have plugged into the female. I'm hoping that you are having no problem removing a single pin/wire from a plug as shown in the video I presented. If so then again get you a tiny screwdriver or paper clip and practice.

Now at this point we are only going to focus on the engine run engine off switch like the picture I listed above. We have the start button behind us so now we'll do this switch.

I want you to put the solid GREEN on the male plug to the solid YELLOW on the female plug.

I want you to put the BLACK/WHITE on the male plug to the BLACK/WHITE on the female plug.

After you do this you need to make sure the GREEN is tied in with GREEN that is our ground wire going to the negative battery terminal. You could actually tie it in with the same green that you used for the start button that is hooked to the BLUE if you like?


Then you need to make sure the BLACK/WHITE is tied to the same BLACK/WHITE on the key switch and then make sure this BLACK/WHITE wire goes to the BLACK/WHITE on the CDI.

Do remember that the GREEN on the key switch is hooked up to our GREEN ground wire, again we use GREEN a lot.

This completes another circuit. Don't forget to do the other wires I mentioned on the CDI and coil. When you are all done get back to me.

JR

[o0ohakko0o]

Ok all done JR I'm sure all is connected up the way you asked me to

[JR]

Ok now we have it where the engine should run. Now we still don't have the charging Regulator/Rectifier R/R hooked up but that's easy as pie.

If the machine has gas in it and the carb is working like it should the machine should run. So here is your options at the moment, pull the spark plug and let's see if the spark plug will spark or make sure it has gas in it and let's see if it will crank and run.

Either way it's up to you, we can wire the R/R after we see because we don't need this for the engine to run. If you want to check for spark or see if it will run then do the following;

Turn the key on
Make sure the handle bar kill switch is in the engine run position
Hit the start button.

BTW does the carb have two wires running to it? This would be a electrical automatic choke if it does it's easy to wire.

Lastly I see the carb has no air filter on it, I highly recommend you buy a uni-filter off Ebay and install it to keep dirt out of the engine.

[JR]

The R/R is a easy one. Coming out of your engine you have 3 wires left that are unused, 2 yellows and a green. I see you have a plug in the R/R that has the following wires, YELLOW, GREEN, WHITE and RED.

Hook one YELLOW out of the engine to the YELLOW on the R/R (either yellow doesn't matter which one)
Hook the other YELLOW from the engine to the WHITE on the R/R
Hook the GREEN from the engine to the GREEN on the R/R
Hook the RED from the R/R to the RED fused wire on the positive battery terminal.

Now if you have head and tail lights we can hook them up also?

JR

[JR]

Did you leave the BLACK from the key switch hooked up to the GREEN/YELLOW going to the solenoid pigtail relay? You didn't unhook the start button GREEN to the BLUE wire did you? I said you could tie in any GREEN ground wire like to the YELLOW wire on the engine kill switch to this GREEN but you must leave the BLUE hooked up too.

We had the engine where it would turn over so you've knocked something loose or wired something else up wrong and changed our starting circuit?

[o0ohakko0o]

SRY the battery wasnt hooked on properly its turning over but not wanting to start i dont have gas right now but what i did was put some start ya bastard down the spark plug hole but its just cranking over and over

[JR]

You need to check the handle bar engine run switch, is it in the RUN position? Might need to pull the spark plug and let's see if it's firing? You may have flooded it?

[JR]

You must be using your phone to correspond on the forum?

[o0ohakko0o]

Ok im on both on my phone and on home computer lol when im out near the bike im on the phone but right now im on my home computer and yes the engine run switch is in run postion and yes i have good spark as i tested.. And for the carby it has one wire like break wire coming out of the top of the carby connecting to the thumb throttle