Wiring harness driving me mad! By lazerorca (Read 13,170 times)

[lazerorca]

I was told... oh it's easy... just match it up to the old one... well... if only it were that easy. the harness I got came with no schematic... the front end of my scooter is a complete mess it looks like. I have colored wires on my harness that are not in the front end... and vice versa. I tried just "matching up colors" kindergarten style making sure my fuse was in. blew two fuses and voltage regulator got a bit warm. I'm lost with this. The old harness looks quite a bit different from the "generic" one that I got. any suggestions?

[redrider]

Tell us what kinda scooter u got ,what kinda engine ,and as many pictures as u can share .What kinda problems where u having before the replacement ?

[Alleyoop]

You beat me to it redrider, need to know what scooter and engine you have there maybe a diagram for it. You could of gotten the wrong harness as well.
Alleyoop

[Bashan]

There are NO standards in the Chinese scooter industry, just generalizations. For instance, the right turn signal circuit is supposed to be light blue wires. If the guy at the factory didn't have those close it might turn out to be another color. The harness is probably correct for some scooter they built for a while but who knows if it will match up with a different scooter. It probably would have been easier to pull all the plastic, strip the wires, and hard wire it from scratch. We can walk you through that if you choose to go that route. If you want to use that harness we'll need lots of pictures and you'll have to use a multi on continuity to figure out where the wires start and end on the harness. Rich

[lazerorca]

50cc Taizhou Chuanl

[lazerorca]

starting from rear... with the lights... green, yellow/white, blue/white match up to a plug, so does green, yellow/green, brown... on the harness I have 2 bundles left... (green, light blue), (orange, green) the bundle left from the back harness is (light blue, orange)...

to the CDI I have fuschia/black, fuschia/white, green/fuschia, yellow/blue, and green... I just plugged them in assuming they were in the right config

to the choke I have yellow, and green/black which matched up to my harness...

to the coil I have fuschia/green and green

now to the stator... what I have on the harness doesn't match cleanly... I have blue/yellow matched to fushia/white and fuschia/black to fushia/black... the plug from the harness only have yellow and white while the plug from the stator has white, yellow, and green...

I have a random plug that I haven't found a match to... it is a fat red/white wire... it comes from the start relay I believe... I also have wire that is green/black... doesn't match to anything either...

I believe this next plug goes to the regulator which originally was mounted on the front of my scooter... it is red, white, yellow, green... has a seperate green wire coming from it as well that I think is a ground wire... to the starter relay I have a fat red/white and fat red wire hooked up... also a red/yellow, and green yellow hooked up... that is all that I have hooked up...

here is what I have at the end of my harness to hook to the front end harness... listed by how they are bundled...

1. light blue, black
2. green, orange
3. light blue, green
4. green/yellow, black
5. green/yellow, black
6. green, white, blue
7. white, blue on one connector and green, light blue, blue, brown, orange, blue/black
8. on a blue connector, I have red/yellow, blue/black, black, brown, yellow, green
9. on a male connector I have blue, blue/white, light blue, orange, yellow/white, brown, black... with a separate green... I suspect this is the one I will need to use now sure...
10. I think this goes to the starter... fuschia/white, red, green, black

coming from the front end harness... here are the wires that need to be matched up...
1. on one connector I have blue/white, green, light blue, red/yellow, orange, black, yellow/white, and yellow... on a separate connector I have green and black/white... then there is another connector where the old harness had a green/black wire hooked to it... I have no clue what it is... the wires are running to this gismo have braided covering... they are black and white and run up close to the horn

[Bashan]

Man, I haven't seen that much fuschia since a gay rights parade went through town! I'm going to have to disect your post bit by bit. It may take me a while, I'm at work.

Mar 4, 2012 18:46:06 GMT -6 lazerorca said:

starting from rear... with the lights... green, yellow/white, blue/white match up to a plug, so does green, yellow/green, brown

[/b]
The green is always ground, if you have a free green you want to attach hook it to a paint free spot on the frame. All of the greens end up at one or two common grounds that connect to the frame. The Y/W and L/W (blue/white) connector comes from the fuel sensor. The G, G/Y, and Br connector is your tail/brake light. The G/Y is the brake light supply and the brown is tail.

Mar 4, 2012 18:46:06 GMT -6 lazerorca said:

on the harness I have 2 bundles left... (green, light blue), (orange, green) the bundle left from the back harness is (light blue, orange).

[/b][/quote]
Light blue is almost always the right turn signal while orange is similarly the left. So the green/light blue, green/orange is the turn signals. You probably have an extra connector there for additional lights that aren't on your bike. It's very common on these scooters to have unused connectors. I would think that's the case with the light blue, orange.

[Bashan]

Mar 4, 2012 18:46:06 GMT -6 lazerorca said:

to the CDI I have fuschia/black, fuschia/white, green/fuschia, yellow/blue, and green... I just plugged them in assuming they were in the right config

[/b][/quote]
You mean the scooter side or harness side? The Y/blue is the trigger coil wire. I'd just run a wire from the trigger coil right to the CDI and plug it in to the right pin:

Same for the coil feed, just use the correct pin on the CDI and go the the non-ground terminal on the coil. The green is ground, you can ground the CDI to the frame and not worry about connecting to the harness. I've never heard of those other wire colors for the CDI. That's why I said it might be easier to hard wire the whole thing. You've got your AC power and kill left. I'd also run right from the stator AC power to the CDI, it's a red wire and just hook to the correct pin and bypass the harness. The kill should be a black/white in the harness connector.

[lazerorca]

I believe fuschia = red...

right side of the handle bar has the starter button and the switch for killing the engine... we have red/yellow, green, black/white, black

left side: hi/lo beam, horn, turn signal

light blue, dark green, gray, black, orange, light green (i'd also like to note that dark green is matched with yellow on the other side of the connector...)

both sets of brake wires are brought together to one set... green/yellow, black

I finally have some photos

This is from my new harness I believe they are the bundle of wires that goes to my ignition



Here is a picture of the back of my ignition...



Here is a pic of the back of the scooter where the harness hooks into the back harness for taillights, fuel sensor, etc etc.. Notice that orange and light blue have no match... I do have 2 unmatched bundles from my new main harness... they are (light blue and green) and (orange and green) wasn't sure if I should just match them and what I should do with the leftover green wires...



Here is a pic of the wires for the stator... notice that there is a three pronged connector with yellow, white, and green while the connector from my new harness just has yellow and white



This is a pic of the CDI. There is no black/white kill... it is replaced by another wire it is replaced by another wire (I believe red/white)



This is a pic of the coil... i believe it is hooked up correctly



These two wires I am a bit unclear as to their purpose... if someone would clue me in that would rock.



I believe this goes to the voltage regulator. I'm not sure if I'm supposed to strap that green wire I'm holding to the body of the scooter. also the voltage regulator was originally mounted up front.



This is a pic of the battery and starter relay... I think it is hooked up correctly



This is the quagmire of sh*t on the other end of my harness



This is what I somehow have to figure out where to hook up everything to the front end harness..



This is horn and blinker unit (and where regulator used to be)... and a gismo I'm unsure of below the blinker unit that has a braided white a black wire with bullet ends...



This is a pic from behind the instrumentation panel



I hope these photos are helpful... if you need more photos just lemme know. I can also shoot video.

[Bashan]

Fuschia is a pinkish purple color that got its name after the flower of the fuschia plant, (reference.com). There can be pink wires and purple wires in harnesses, calling them red is a lot more definative.

Your ignition switch works by connecting the red from the battery to the black power supply wire when on. When off it connects the kill to ground to stall the engine. You have a red/white kill into the CDI that needs to connect to one of the greens in the ignition, the other ignition green needs to ground to frame.

Third pic: The top connection is fuel sensor and looks OK. The bottom connectors show the turn signal wires hanging free. To make them work connect the like colored wires from the harness side to the wires hanging free. You'll have to ground the greens from the harness on those two connectors and make sure the signal sockets are grounded.

Fourth pic: Connect the whites and yellows and ground the green.

Fifth pic: The white/red is your kill, the position is all that matters on the CDI pins. So the green/red is your coil feed.

Six pic: coil is good

Seventh pic: I have no idea and if everything operates I wouldn't worry about it. They wire stuff in all the time for other type scooters.

Eighth pic: Yep, standard R/R fare. Plug it in and ground the green to frame.

Ninth pic: Looks good

Tenth pic: What a mess. The blue/white/green is headlight. Light blue/ green and orange/green are turn signals. Grey is flasher, black is power from the red. And...you're right, that's a mess. I gotta go...leaving work. Rich

[sprocket]

Notice how I avoided this thread ;-) Great photos..

[Alleyoop]

Sprocket you chicken snit(HAHA), Notice I didn't say squat either(HAHA). ;D
I know I am not an Electrical Guru I can get by but not with that mess. ;D
Alleyoop

[bcgreatness]

i wonder where john is, hes usually the electrical guru. he helped me identify a bunch of the wires on my scoot.

[sprocket]

John is out there somewhere buying old Vespas I think...

[Bashan]

Mar 2, 2012 4:35:30 GMT -6 Bashan said:

It probably would have been easier to pull all the plastic, strip the wires, and hard wire it from scratch.

[/b][/quote]