Back at it...philosophydoc rebuild By philosophydoc (Read 10,888 times)

[tvnacman]

well now Phill is it running yet ? did the diesel do the trick

[philosophydoc]

Not running yet, but only because I still have six cut wires I need to trace and connect up before I can try to turn it over. I need to get some advice from Doc JR about how to proceed.

[tvnacman]

well Phill don't wait post pics of what you have , and what area of the scooter they are located . JR is of about the best help around here , but not the only help . Well let me tell you about myself , I will start with the anatomy of my screen name TV=TELEVISION N=AND AC=AIR CONDITION MAN=MAN , with that said the TV part, which is no more , was component lever repair diagnosing and replacing small components on circuit boards . When it comes to electrical I'm pretty good , however auto and motorcycle experiance is limited , but maybe surprisingly good .

JR has a rather large garden he maybe tending too it .

John

[Alleyoop]

John,
Your just to clever for us what that call sign
Alleyoop

[philosophydoc]

Okay, the original discussion of all this began here:

scooterdoc.proboards.com/index.cgi?board=250cc&action=display&thread=3375

I bought a scooter in parts, and am putting it back together. The mechanicals aren’t that tough, but the wiring is the issue. I have accounted for all the wiring (i.e. I have made all the connections) save for 6 cut wires.

The colors of the cut wires, coming down from the instrument cluster are:

Red/Green
Yellow
Yellow
Black
Pink
Blue/Red

I also have a fuse box with 4-10 amp fuses, but no place to connect it. (WARNING: The box o’parts that came with the bike had several “extra” parts not connected to the bike, so I cannot even be sure the fuse box IS part of my scooter. But since a faceplate on the bike identifies it as a 2008 Jonway YY250T-2, which does have a fuse box, I am assuming this goes with the bike).

Coming out of bottom of the fuse box are 8 wires (Four fuses x 2 wires to each fuse = 8), terminating in a six pin (flat blade) molex connector. (How do you get eight wires into a six pin connector? Three of the eight are black, and they are spliced into a single wire). So the colors at the connector are these:

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


I cannot find any wiring diagram that seems to make sense of the wire colors I have, and need to “trace” the cut wires, but I have no earthly idea how to do that. I have a multimeter, but no experience using it.

The ideal solution (more hoped for than anything else) is that the 6 cut wires “connect” to my 6 pin molex connector. Colorwise, there are three matches between the cut wires and the molex connector (between the Yellow, Black, and Blue/Red wires). That leaves me with three sets of unmatched wires:

Cut wires

Red/Green
Yellow
Pink

Molex Connector from Fuse Box
Brown
Brown/Blue
Light Blue/White

So at this point I’m stumped as to how to proceed. Battery is not hooked up, but I can do that if need be.

[tvnacman]

secure the wires and put a battery in it and see what works .


John

[philosophydoc]

Okay, hooked up battery, turned key on (Omega symbol, correct?).

What works: passing light, radio, horn

Turn signals, license plate light, brake lights do not work (tried signals, squeezing L and R brake handles...nothing).

I am currently waiting for a water pump impeller cover gasket, so I did not try to turn it over, as the cooling system is drained.

Also, is this a extension for adjusting the A/F screw? It connects to the bottom of the carb....? Any idea where it attaches?

[insanetexan]

That is a drain line for the Carb. It should run down to the side of the CVT case and attach to it.

[tvnacman]

phil a quick 20 or 30 sec run should be ok once !!!!!!

[philosophydoc]

Okay -- gasket for water pump arrived today, so it is in (loctite on bolts). Also put in a new magnetic oil plug, added oil, and just finished adding coolant (Prestone 50/50).

I will try to start it up tonight or tomorrow, but as I was burping hoses, I came across something I wasn't expecting.

When I replaced all the hoses, here is one hose that now looks odd to me. Look at the hose exiting on the left from the radiator cap opening:




It loops around and terminates at the carb here (it is the center tube -- the green tie just to the left of the red tie, red denoting the fuel line):



Is this correct? Does this mean that coolant can flow in this line? I am certain I didn't misconnect the hoses -- this is how they were when I received the bike). Is this a mistake, or okay?

Thanks

[Cruiser]

Some carbs do have a connection to the cooling system. I believe it's used to prevent carb icing.

[Jeff]

Do the instrument panel lights also work? If so, sounds like everything works but the brake lights. That cut harness sounds like it went to an alarm system and someone just cut it out.

Usually the wires don't really change colors from one side of a molex connector to the other side, but I've seen the shade of color vary a lot. Dark red could be light red on the other side. Stripes will vary in color shade and width.

Trace wires from the brake lights back up to the handle bar controls to find the loose connection. Actually you want to find where the two handle bar controls connect to the main harness. The bad connection will be between that spot and the rear lights.

[philosophydoc]

Thanks, Cruiser...I've never run across a carb that had a cooling line run to it.

Jeff, so far, with battery hooked up and key turned on (but not starting bike) , the horn, radio, and passing lights work. Tried brake lights, but no go.

Will keep you posted when I try to start it tomorrow...

[philosophydoc]

Well damn, damn, damn...

Hooked everything up - battery, gas lines, etc. -- turned key (horn works, radio, fuel gauge, passing light), held brake lever, pushed starter button, and...

Nothing.

No click, no sound, just silence.

And to add insult to injury, I found one more connection that I have no idea where it goes...



The "mytery molex" houses one black/white and one green wire. Next to it (on the right) you can see six cut wires I am still flummoxed by.

Does the location of the newly-discovered connector give anyone a clue as to what it should connect to? As the wiring harness descends from the instrument panel, everything "downstream" of these two sets of wires I have accounted for: CDI, R/R, brake, tail lights, turn indicators, license plate light, fuel gauge indicator, etc. I have one nine pin connector that is not hooked up to anything, but that appears to control the remote start, alarm, etc. which I have no desire for anyway. As you can see in the photo, the main wiring harness splits into two, and top half contains 4 bundles of wires: one bundle goes to the coil, one goes to the radiator fan, and then I have the mystery molex, and my set of cut wires. The lower half (of which you can only see the black sheathing) contains all the wires that go to the CDI, R/R, etc. Here a picture to show you how that all connects up:



Any help would be greatly appreciated.

Even when I connect the taillight assembly (which is completely off the scoot), pulling on the brake levers or activating the turn signal has no effect. This could mean the kill switch tied into the brake levers isn't working...?

I have been avoiding removing the front cowling and slitting apart all the main harness's sheathing to physically trace the wires, but I fear I may have not any choice at this point.

I have a multimeter, but little experience using it (much more comfortable with mechanical rather than electrical problems).

Frustrating, but I'm not beat yet...advice on a next step?

[insanetexan]

Not sure if I missed it in this post but, do your brake lights work? The brake lights from what I understand need to work before the 54B will start.