Newbie with wiring question By philosophydoc (Read 10,016 times)

[philosophydoc]

Greetings -- have been lurking for a while, and come on bended knee for your sage advice and wise counsel!

Purchased an Apollo Ani 250 (partially disassembled) in 2009. Owner swore "all the parts are there -- you just have to put it back together!" (I'll buy your swampland in Florida, too...) I am finally getting to it, and have four electrical questions.

FULL DISCLOSURE -- I have scoured the board as best I can to make sure I am not asking what has already been answered. The scoot has a CFMoto engine, and I have looked at a number of wiring diagrams (including the CFMOTO 250 CLONE file in the Library here), and still have some questions. I will always try to treat your time as the precious resource it is...

(1) Where does the fuse box connect to? From this discussion I know that the fuse box does go with my bike (thanks for the photo, Cruiser!) Here's a photo of my fuse box and connector:



I have found nothing on the wiring harness (or elsewhere on the bike) that fits this connector. But this leads to my second question:

(2) When I got the bike, one set of wires had been cut. Just as the wiring harness descends from the front fairing and turns to head back to the engine compartment, it splits into two strands. The top strand has been cut:



...leaving six unconnected wires. The fuse box connector has six pins, so is my mystery solved?

(3) Since each plastic molex connector appears (?) to be unique, I have been working under the assumption that if a replacement part I have purchased (i.e. new CDI) fits into a connector coming off the wiring harness (and I mean it perfectly fits, such that tabs on either connector interlock correctly), then the two are meant for each other, even if the wire colors may not match perfectly. Am I right?

(4) And finally, with the exception of the fuse box, I have been able to make connections to everything on the main wiring harness save for save for the last connector (i.e. the longest final strand, at the very end of the wiring harness). Here's a photo:



The connector on the right connects to the taillight assembly; the one on the left (I have looped it around to get it into the picture) is a nine pin connector, with 8 wires connected to it. Again, I cannot find anything to which this should attach. Here are all the other connections, correctly connected (or so it appears to me):



Apologies if I am being thick...I don't profess to have a lot of skill reading wiring diagrams, and I have done my best to trace everything via colors...

Again, many thanks in advance...

--Mark

[Cruiser]

Welcome to Scooter Doc, Mark.

Looks like this wiring mystery could best be solved by someone with the same type scoot as yours. The wiring diagram we have is for the YY250T/RO clone. Yours is a different body design which could make it difficult without the exact wiring diagram for your scoot. Here is a site with a cross reference listing of scoots which are the same as or similar to your scoot:

www.motopartsmax.com/index.php/main_page/vehicle/vID/1142

This will give members with the same scoots a heads up. I will leave this thread alone for now to let members know that you are a newbie. Eventually this will have to be moved to the tech section for more thorough diagnostics.

[philosophydoc]

I will check the wire colors tomorrow on the cut wires to give you a clearer explanation.

I knew I came to the right place...many thanks, and I'll update things as soon as possible.

But am I correct in assuming that where molex connectors match (exact male/female match, but not necessarily wire color) that it's likely correct? If not, I fear I'll really be lost...!

[Bashan]

Mar 23, 2011 21:09:57 GMT -6 philosophydoc said:

[But am I correct in assuming that where molex connectors match (exact male/female match, but not necessarily wire color) that it's likely correct? If not, I fear I'll really be lost...!

Yep, sorry to say that's true. I read an article not too long ago about the factories that make these things. It seems that toward the end of the day the workers just start grabbing whatever wires that are laying around from the day's work and start putting them in Helter Skelter. So you can't always rely on the wiring diagrams and often must trace the wires to determine their function. Another confusing issue is they build a wiring harness that will fit many different scooters. So you may find blind alley connectors that are often mistaken as a part of the harness that came loose. You just have to use the diagrams as a guide and not a definative reference. A must have in your tool box is a continuity tester to help trace wires.

Hey, you guys better tighten it up around here, this guy is a doctor of philosophy and can think you into another dimension . Glad to have on board learned sir and if you need any help getting around the forum just click on my handle and send me a PM. I'm going to move this thread over to 250cc so you can get a few more tech eyes on your queries. Have fun, Rich

[philosophydoc]

Okay, first update....

Fuse box has eight wires coming off the base of the box:

Blue/Brown	Black
Blue/Red	Black
Blue/White	Black
Brown	Yellow

These eight wires terminate in a six blade molex connector -- the three Blacks all join together, leaving:

Blue/Red	Black
Blue/White	Black
Brown	Yellow

The cut wires are:

Yellow
Yellow
Blue/Green
Blue/Red
Black
Pink (really)

I am poring over the Lance Duke diagram right now, and while the "Disaster Box" their shows three 10 amp fuses, my box has four. Again, my box is EXACTLY like the one Cruiser has:



...with the exact same label on the inside. So combining the label and wire colors, I have (tentatively) this:

Wires to Fuse	Fuse Label
Yellow and Brown	Light
Black and Blue/White	Horn,Meter,Winker Relay
Black and Blue/Red	Brake Switch
Black and Blue/Brown	Cooling Fan

Any idea which "Light" the label refers to?

Thanks again...

[tvnacman]

welcome Phil
this may sound like it is from left field , have you located your regulator ? will that plug , reach and plug into it ?

[Cruiser]

I believe the "light" fuse refers to the headlights.

[Cruiser]

"The connector on the right connects to the taillight assembly; the one on the left (I have looped it around to get it into the picture) is a nine pin connector, with 8 wires connected to it. Again, I cannot find anything to which this should attach."

Do you have an alarm/remote start system on your scoot? This 9 pin connector is similar to the type that would be used for the alarm. The alarm is usually in the front, but it physically be located anywhere.

[philosophydoc]

tvnacman, look at the last photo in my initial post, and I believe you will see the regulator/rectifier connected, resting on the running board, with a few yellow wires running to it. Or am I mistaken?

[philosophydoc]

CDI:

Black
Black/white
Red/white
Green
Black/yellow

So it is just as you said, except instead of gray/white I have black/white. And a similar substitution occurs on the nine pin connector with eight wires:

red
black
light blue
orange
red/yellow
black/white
brown/white
green

...no gray/white here either.

And finally, the cut wires:

Yellow
Yellow
Black/Red
Red/Green
Pink

(Sorry about the question mark after pink...as I looked over the Lance duke wiring diagram, I could not find any "Pink" in the legend. But it is clearly pink.)

Finally, a picture and a question:



What is this? I don't think they were connected when I got the bike, but (again) the connectors and tabs fit perfectly. But I am bothered by what appears to be a "switching" of the red wire (i.e. rather than connecting red-to-red, it appears to connect red-to-black, which sets off alarm bells for me. I have not examined the connector to see if it crossconnects (such that a red going in the bottom is connected to the red coming out the top) but since that seems to go against any connector I've seen in the past, I am skeptical.

Again, many thanks...

[philosophydoc]

Oops..forgot to add that scoot DOES have remote start. Not sure about alarm, but if neither works it's no big for me.

[philosophydoc]

SO sorry for my errors/omissions, of which there are one of each:

(1) Of the six cut wires, the one I left out is BLACK. The amended list of cut wires

Yellow
Yellow
Blue/Green
Blue/Red
Black
Pink

(2) (Because I tried to use HTML tables, and screwed them up) the six wires attached to the connector from the fuse box are:

black
brown
brown/blue
light blue/white
blue red
yellow

(Don't know the protocol, but from now on, "blue" will mean a darker blue, and lighter shades will be "light blue")

And my battery is dead, so I'll have to order one to do any testing.

You are all lifesavers...

I'm heading home, so I'll check the radiator wiring and get back to you.

[philosophydoc]

Okay, two wires going to the thermostat (located at the base of the radiator, correct?) are orange/white and green.

And if this is any help, the two wires going to the fan motor are pink and orange/white (though these wires connect to a molex connector which changes them to red and blue). In other words:

pink -- to --- red--- connect to fan motor
orange/white -- to -- blue --- connect to fan motor

[tvnacman]

Mar 24, 2011 21:45:46 GMT -6 philosophydoc said:

tvnacman, look at the last photo in my initial post, and I believe you will see the regulator/rectifier connected, resting on the running board, with a few yellow wires running to it. Or am I mistaken?

the plug looks like a regulator plug from another scooter

[philosophydoc]

The latest update...

(1) I am now convinced that with the board's help, I can get this bad boy up and running. So I ordered a multimeter today, and am researching batteries as mine is dead (local scoot shop -- very unhelpful -- did test it and confirm it's done). Advice on a battery? Came with a GTX7A-BS, but as this bike appears to have parts from everywhere, that means little. Since most 250s have a 12 volt 9AH, that's what I'll look for, but any advice on brands would be appreciated.

(2) Further examination reveals that the plastic seat insert (battery holder, gas tank, etc.) has a tag that claims this is a 2008 Jonway YY250T-2. (But the Jonway 250T wiring diagram in the tech section doesn't appear to fit this bike, as I have a fuse box and none is listed there). Still, using that as a reference, that means I should look for a 12 Volt 9 amp battery, that is no taller than 5" (compartment won't appear to handle much more).

(3) Since the scoot is apart right now, I will (a) replace all the vacuum hoses with sturdier, 5/32nds ID vacuum tubing (current tubes look flimsy and aged), replace all wire clips with hose clamps, and replace the fuel lines with 1/4in ID mesh re-inforced fuel lines. Seems like cheap insurance to me. Again, if this foolish stop me now...

(4) I will wait to get this thing running before looking at swapping out roller weights, changing incandescents for LEDs, etc. Really, mechanical stuff doesn't faze me - I'm no whiz, but I'm patient and thorough, and that often is all one needs. But electrical really frazzles me, so I am grateful for all your help.

I have confidence! I have inspiration!

I think...