Headlight won't shut off By gonack (Read 3,547 times)

[gonack]

When the battery is connected the headlight is on all the time otherwise the scooter runs fine, I checked the wiring and don’t see any thing that looks burnt or melted, the only way to shut the light off is to disconnect the battery?

[jct842]

You fail to tell us what scooter you have.

We do have generic wiring diagrams for most chinese scooters on this forum.

[Alleyoop]

Let me ask this question, Did you do anything to the scoot, did you add something or re-wired something or changed anything. Also do you have a LIGHT SWITCH on the Right handgrip to turn off and on the lights? If you do not have a LIGHT SWITCH then is mostly your KEY SWITCH allowing juice to flow even on the OFF position.
Alleyoop

[gonack]

After I posted I realized I had forgotten some needed information, it is a RunMaster 150cc, and I bought at a garage sale it has 2 actual miles on it the party I got it from had hooked the battery up backwards and the fuse was blown I replaced the fuse and hooked the battery up correctly and that’s when I noticed the headlight wouldn’t shut off. It does have a light switch on the left hand side but it’s only for putting lights on high and low there is no on and off switch. Hope this helps.

[Bashan]

I think I have you figured out but first I'd like you to try a couple things.

• Hook up the battery and see if both the high and low beams work.
  
• With the battery hooked up pull the yellow wire off of the rectifier and see if the headlight goes off.

[gonack]

The high and low does work, and not being a scooter expert where is the rectifier located I know what they look like just don't where it is on the scooter.

[Bashan]

Usually they're under the front cowling, the one with the headlights. Sometimes they're down by the battery or on the right frame rail by the CDI.

[gonack]

After looking on the internet I located the rectifier, I removed the yellow wire nothing changed but noticed the pink wire was warm so I rehooked the yellow and removed the pink, the hedlights were off when battery was hooked up and when I started the scooter the headlights came on and I could use high and low beam setting and after about a minute the lights went out and now they don't work at all and the pink wire still gets warm to almost hot.

[Bashan]

IF the wiring diagram on the generic user manual on the Kinroadusa.com site is correct, the pink wire is the AC feed for the charging circuit. This is usually a white wire but there's a lot of variation. Here's a screen shot of the stator, rectifier, and light switch:

The red comes from the battery and the pink and yellow from the stator. The yellow powers the headlight when the stator cranks up. I thought your rectifier may be shorted but the light should have gone out when you pulled the yellow. The frustrating thing is that the diagram is cut off at the bottom. Here's a screen shot of the whole diagram:

As you can see the hot wire from the battery connects to some circuits out of view on the PDF. If you can get me the whole diagram out of your owners manual I might be able to figure out where the short is.

[Bashan]

Hey....I just thought of something, what if the rectifier is shorted from the red to the pink. Then the energy would go through the stator, back up the yellow, and connect BEFORE the rectifier to the headlight.

That would explain why the headlight went out when you pulled the pink but not the yellow. Then when you started the bike the yellow supplied the headlight so it came on. I bet if you checked the voltage on the yellow it would be way over 12v AC because of the bad rectifier. That blew the bulb and the headlight quit working. Check your bulb and see if it's out and check the voltage on the yellow. If it was me, I'd order a new rectifier and see what happens.

[gonack]

I went ahead and ordered a new rectifier I should have it by 10/31/12 and I will let you know if that fixed it, till then thaks for all the help.

[gonack]

I got the rectifier today and installed it, you were dead on! Everything runs fine now. Thanks, you got another scooter back on the road.

[cdoublejj]

Haha Awesome!