Understanding Kill switch/starter button wiring? By sillylittleboy (Read 4,743 times)

[sillylittleboy]

I thought I had my scooter fixed and it was the starter relay. I could have sworn I measured a voltage on the control wires going into the relay when I hit the starter switch... but now I'm not getting anything on those wires.

So, I've got a Tao Tao Powermax150, which overall is a pretty generic GY6 scooter. It starts fine if I jump across the terminals of the starter relay, but I'm not getting the control voltage (?) to the relay.  I checked out several of the wiring diagrams featured on here and I'm trying to determine testing procedures to narrow down where that control signal to the starter relay is failing.

I've got two sets of two wires coming out of the kill switch/starter button box on the right handle.  Two of those wires that are wrapped together coming from that switch both register ground whether the kills switch is on or off and whether or not I hit the starter button.  That can't be right, is it?  The other set of two wires register nothing (no voltage or switch to ground for either terminal).  I know between this switch and the control wires going into the relay there is a brake switch in that circuit that must be completed to allow the current to flow onward to control the relay (why you need to apply the brake before hitting the start button or nothing happens) and I've been holding the brake on while I test voltage or continuity 

What I'm trying to determine is what exactly should be coming out of the kill switch and starter button.  In reviewing the wiring diagrams it looks like the kill switch when on just transfers ground from one side (terminal) to the other side (terminal).  When I look at the starter switch, it initially appears to be doing the same thing - two terminals with ground on one terminal and then a wire that connects to the starter relay on the other terminal of the starter button.  Either way it would appear that each of those switches (kill switch, starter button) is simply connecting the two terminals of that switch when turned (kill switch) or button depressed (starter button) or perhaps passing on a voltage/circuit to those control terminals of the relay.

Any suggestions on how to test or determine where the failure might be occurring. I'm ready to just replace my current "Kill swtich/starter button" switch box, but it kind of looks like a pain in the butt to get to it and make any changes. So I'd really hate it if I replace that switch box and it doesn't fix the problem.

[sillylittleboy]

FYI - This wiring diagram would appear to match my wiring right down to the colors of the wires. The control wires going into my starter relay are R/Y and G/Y just like this diagram:

GY6 Generic Wiring Diagram

[cyborg]

There should be a hot 12v going to the starter button and then two coming out to go to the brake switches and they complete the circuit to the solenoid

[sillylittleboy]

Thanks... through this info, a little studying of the wire diagram, and a bit of poking around with a multi-meter and I have now determined beyond a shadow of a doubt that it is the starter button that is bad.  Just to prove me point the button will depress now but not spring back.

I watched a video on troubleshooting starting issues and the videographer had a test for the kill switch. Removed the two-wire plug from the CDI and using the audible continuity check setting of my multi-meter I attached one probe to ground and the other to the black wired terminal of that plug.  With the key off and kill switch off = BEEEEEEP. When I turned the key on and the kill switch on = no sound.

Took readings off the four wires coming from the kill switch/starter switch unit and again the kill switch either connected the two terminals or didn't, but the starter switch did nothing. Whether I depressed it or not there was no continuity between it's two terminals.

Hey, this was a very educational endeavor.  I learned all about the electrical ignition systems that will hopefully serve me well with any future starting issues.