2005 Tank KTMMEX 50cc (I believe) By fortythreesportyme (Read 3,657 times)

[fortythreesportyme]

Newbie here. Recently purchased a 2005 Tank 50cc scooter project for my 15 year old son. Engine tag: TK1P57QMJ. Body panels are marked Jon Way and some city in China. I pulled a similar wiring diagram from the library here (this wiring needs
to be redone) and a couple parts I am unsure of. Looking for photos of what this is supposed to look like minus the body panels and seat. HELP!

[Bashan]

1p57Qmj is your standard 150cc Chinese horizontal engine/scooter. Look in the manuals section in the library for GY6 manuals and you'll see all kinds of nudies of the scooters.

[fortythreesportyme]

Thank you! Much appreciated.


"CCS or POS, it's the call of the beholder.." -Morgan Freeman

[fortythreesportyme]

Hello again!

WELL, it has been quite the experience trying to get this $100 Tank scoot back to working condition. The wiring had been botched severely so installed a new wiring harness from PartsforChineseScooters. As well as missing and badly damaged plastic body panels. Galv.mesh, two-part epoxy, and bondo to repair and rebuild some missing and broken parts. It is Frankenstein! I will share photos from my Tab4 here shortly.

Here is what I've come up with. After using a couple of different wiring diagrams found here in the Library, and reading up on nearly every related post about the gy6, electrical, etc. I've connected everything that plugged in. Then started connecting up front at the regulator, the start button, horn, brake switches, etc. Followed the diagrams to the wires- keeping in mind the color wasn't as important as the wire and it making its connection. I couldn't get it to crank until I had the rear bulb in. Found the socket was damaged and might have been shorting out somehow. Cranked fine, fired and ran a few seconds. Then my coil blew a smoke ring and spat a pinhole of tar oozed out so I shut the key off and disc.the battery. Ordered a new coil and enjoyed the pleasant smell of burning electrical.

There is what appears to be a resistor with two prongs on it, mounted on the front light mount where the regulator is mounted. Small aluminum star-shaped deal with heat sink fins. I have not seen anything in diagrams of what connects up to these two prongs, shaped like a T. Top is horizontal and bottom is vertical. I am wondering what caused my coil to puff smoke and toast itself. Direct short? Too much juice somewhere? Also- fuse at battery lit (but did not burn out). Something is not right. I have not connected any front lights or signals, they are capped off.

I find it odd that the key switches current to the start button, and from the key the black becomes hot (carries voltage) and only connects up to a couple of other blacks- according to the diagram. All of the greens are negative/ground. And that the green/yellow tracer is switched by the brakes and connects only to the solenoid and the brake light.

I have my new coil installed but not connected. As I do not want to smoke another one just yet. At $ I want and need to be sure. Help?

[Guitarman]

That's a charging diode and you had it hooked up backwards.
Use a meter and find which way has the high resistance and then you'll know which way to connect it.

This is where I got my new one.

[Alleyoop]

I find it odd that the key switches current to the start button, and from the key the black becomes hot (carries voltage) and only connects up to a couple of other blacks- according to the diagram. All of the greens are negative/ground. And that the green/yellow tracer is switched by the brakes and connects only to the solenoid and the brake light.

The START BUTTON all it does is GROUNDS the SOLENOID it is the RED/YELLOW WIRE. The only juice to the SOLENOID should from the brake switch and pushing the start button completes the circuit.
And your right the KEY on makes contact with the BLACK wire which in turn feeds anything else needing 12volts.
Alleyoop

[fortythreesportyme]

Thanks Guitarman and Alleyoop. I did not have and do not have the charging diode connected- have no diagram that shows it or what connects to it.

Should the coil have any current to it with key on? Without brake applied or start button being pushed?

As I have checked and rechecked- here is what is going on. I have current to the coil as the key is turned on- with no brake depressed and not pressing the start button. I reconnected my toasted coil- and with key on, it and the wires get warm. Whereas turned my coil to a burnt offering with a side of tar.

Something awry and amiss, I think it is Chinese. An American is trying to make sense of it.

Any help very much appreciated!
Thank you Sirs!

-Matthew

"43 isn't old if you're a tree."

[Alleyoop]

The coil should not be getting juice So you have wires connected to the wrong things.
The Coil gets juice FROM THE CDI and only when it gets the signal from the PICK UP COIL to release the voltage to the COIL.
Can you take pictures of your CDI wires and COIL. Some coils have two wires 1 ground and one wire coming from the CDI to feed it voltage if it only hase 1 wire then it must ground to the frame.

DOES YOUR CDI LOOK LIKE THIS and does it have 3 wires on the 4 plug side and 2 wires on the 2 plug side or only 1 on the two plug side.

[fortythreesportyme]

Thank you for your information! I checked here to make certain the wires in the plugs from the new harness matched up to the aforeshown CDI photo, as well as the coil wires and solenoid wires.

Here are the photos.

[Alleyoop]

Test the RED WIRE with KEY ON AND OFF and and see if it has JUICE, It should not have juice. Now take look at the WIRES on the stator one set should have a plug on it which connects to the R/R for charging and some lights.

THEN THERE SHOULD BE TWO MORE WIRES WHAT COLOR ARE THEY AND ARE THEY BOTH CONNECTED TO SOMETHING?

Excuse the caps but the info for that is very important.
Alleyoop

[fortythreesportyme]

Ok. I tested the red with key off and on, and neither show any current.

The 3 wire plug from stator is yellow, green, and white. Heavier gauge wire. Tracing them they connect to the regulator up by the horn. The other two wires from the stator are red/white and red/black only connect to the cdi.

The front end of harness has regulator plug (6 pin using 5 wires) and 2 small pin-type connector blocks. None of those have the red/white or red/black.