electrical problem By puddle jumper (Read 1,624 times)

[puddle jumper]

I have a new scooter: LINK
I had to replace the ignition switch because it was broken. When I unhooked the old switch and went to plug in the new one it blew the fuse. So I tried to replace the fuse not disconnecting the battery it blew again. So to further more matters I disconnected the battery opened the fuse block and did the ole' foil around the fuse trick. Well that didn't work either. So I had to unhook the battery and brought it in to see if it would charge(the whole time I think I drained the battery) and I don't know if that will help any either. But why would it blow a fuse it was working just a few mins before, and is it possible that the ignition switch has to be bolted on and acts like a ground to the system?

[Bashan]

You have a short, or you've got the positive and negative backwards. When your fuse blew it was protecting your scooters electricals from the erroneous connection. Never ever ever never try to connect across a blown fuse, you can do some serious damage. The chances of the new ignition switch being bad are very slim but here is a link to test it. It doesn't have to be in the bike, you're testing the switch all by its lonesome:

SCOOTER DOC IGNITION SWITCH TESTING

I apologize to anyone that tried to use this procedure before this morning. I don't know what I was thinking but the nomenclature was totally wrong; it's fixed now.

No, the switch doesn't ground by bolting it in, the green wire does all of the grounding. It runs from the switch back to the main ground connection on the frame behind the battery. If your positive and negative are correct, and your switch tests OK, you're going to have to do some wire tracing and find the short. Rich

[puddle jumper]

After some trial and error I figured out that it is the wrong switch and I'm going to call and get another because some reason the wiring is not right and it melted it trying to hook a meter up to it so its junk. I would however like to know were I can find a wiring diagram for my poor little scooter. it takes a lickin and keeps on tickin

[Bashan]

This is in our electrical tech section. It's generic but it should work for you. There's more wiring diagrams in Tech if you want to peruse them. You might want to put the name and type of your scooter in your signature, it helps in our discussions ;D. Rich

[puddle jumper]

Thanks for the diagram Bashan I, I called the co that I bought the scoot from and told them what happened and believe it or not there is about 4 different switches for 4 different names and all wired different. but I hope the new one that is sent to me now will work. Thank goodness I bought a meter.

[puddle jumper]

Well to tell you the truth I fried the new switch not thinking of a difference in models, but you learn and you have it right as far as the wiring down to exactly what I have. Is it though possible to get a new switch with the same wiring and move the wire's around so they are correct?? But I will say I put the old one back in and it works I'll deal with that until it breaks and can't be fixed after all its the housing that is broke not the wiring.

[Bashan]

Oct 8, 2010 20:00:45 GMT -6 puddle jumper said:

Is it possible to get a new switch with the same wiring and move the wire's around so they are correct?

Absolutely, the wires should come out of the harness if need be by pushing down on the retaining tab with a flat micro (glasses) screwdriver. Then bend it back up and insert the wires into the harness where you need them. Use the multimeter and test the wires for continuity with the switch in the OFF position and find the two that position connects. Make sure they end up going to the kill and green ground wire. The kill may not be black/white (mine is purple) but it will be the only one in the scooter side of the harness that isn't green, black, or red.

SWITCH OFF CONNECTS THESE WIRES

Then test and find the two connected in the ON position and hook them up to the red and black wire:

SWITCH ON CONNECTS THESE WIRES

Now I must respectfully disagree the the venerable and loquacious Dr. JR in that connecting the black and green would cause a short. The black nor green is energized so they could not cause a short. However, connecting the red to the green would obviously cause a short. To tell you the truth, I'm not sure what touching the red to the kill would do. The CDI IS grounded so I guess it might fry it. I'm sure as hell not going to run an experiment to find out! Rich

BLACK, GREEN, and KILL NOT ENERGIZED