Sachs SX1 trouble . By fj12rider (Read 2,266 times)

[fj12rider]

Hey guys , new here , good forum .

OK . I have a Sachs SX1 (well my daughter does) and I`m having real issues with the lights . I bought it yesterday spares or repair as a non runner , apparently , which it wasn't , the engine was the least of the problems .

So I got it going , and now I can`t get the lighting working . The rear light works fine , The side lights work fine and the indicators work fine . The headlights on the other hand are not working.

I`ve tested the feed to the dip switch (high / low beam) and thats dead , I`ve tried running a feed to the dip switch from the rear light, something I would normally do to fix the prob if the wiring was gone , but it shorts. If I disconnect the lights on switch on the handlebars , then I can run a feed direct from the battery and both dipped and high beam are fine , if I reconnect the switch , it shorts .

In the switch itself , the BLACK wire appears to be the live and the BROWN is the ground , this seems bizzare to me , I have traced it all the way back to the ignition and it is indeed live all the way back .

I must say that someone has been in there with a soldering iron previously , so really I`m looking for a wiring diagram for this bike although I`m not holding out much hope on that .

Can anyone help me with this bizzare chinese nightmare ? I`m glad I ride a Jap bike ..lol

Thanks

[rob63]

Do the side lights work just by turning the ignition on or do you need the engine running ?
I`m presuming the on off switch is a 3 position off/side/head, if so then there should be 3 wires going to it, one feed to the switch, one feed from switch to sidelight, one feed from switch to hi/lo switch.
When you run a feed from the battery are you putting that to the hi/lo switch or direct to the headlight bulb ?

[fj12rider]

Hi thanks for your reply , I'm putting the battery feed to the hi/low switch, I think there a 5 wires in the switch , i will check tomorrow , and yes it's a 3 position switch . I think the extra wires work the dash light , and the rear light .

so one for , tall light , dash , side lights , live feed to hi/low . Dash light , rear light , side lights all work , head light doesn't. Bulbs are ok (there are 2 headlights) . 

I'm going to battery feed each of the lives tomoz and see which wire does what . The switch it's self is absolute garbage . Vey flimsy , loose as hell but seems to function , well to a point. The indicator switch is just as bad , Kinda of rattles around , I think I may have to replace the switchgear to be fair which is crazy for a 2008 bike , my 1991 fj1200 works just fine .lol.

thanks again, 

[rob63]

Yes the switches are a bit flimsy. You could pull the plug off the back of the 3 position switch and find which one of those wires is the feed from the ignition. The pare a short piece of wire at both ends, pop one end into the live feed terminal of the plug, and then pop the other end of the wire into each terminal on the plug in turn. You should be able to find out which wire feeds which lights. Once you`ve located the wire which goes to the hi/lo switch, you can work from there.

[Alleyoop]

Here are some SACHS Wiring Diagrams which may help.
Alleyoop

www.mopedarmy.com/wiki/Sachs_wiring_diagrams

[fj12rider]

Thanks guys none of those diagrams are for her bike but I'll see if anything looks similar , many thanks . Couldn't do anything yesterday because of the weather hopefully I can get out there today .

[fj12rider]

OK here is where i`m at .

I have sussed that I have the following

pink - unknown (not connected)
black - positive from ignition
yellow - negative (not connected)
blue/white - main headlight
brown - side lights

now , i have a switch that looks like this


I`ve wired it now as in the pic and i have break lights , dash lights , headlight , side lights. BUT, i have 2 wires left over and cant work out what they are for ? Any ideas what they might be ?

[JR]

pink - unknown (not connected)
black - positive from ignition
yellow - negative (not connected)
blue/white - main headlight
brown - side lights


This is only partly correct if it follows as most. There should be no ground to the light switch, period.

Do this test, start the scooter and see if you have voltage on the "yellow" wire with the volt meter black lead grounded to a true ground like the negative side of the battery. You must start the scooter to do this test.

If you do then I'll tell you how to wire this correctly. Will be gone this afternoon for a spell but will check back in.

JR

[rob63]

If as JR states, the yellow is a 'helper' feed from the stator which will give voltage when the engine is running. Then the pink could be connected to a ballast resistor somewhere, this would take away excess voltage fed by the yellow wire.
It`s quite a while since I came across a similar circuit so could be wrong, but I seem to recall the pink having voltage feed with the engine running and the 3 position switch in the off position.

[JR]

Nope in this case pink = hi beam.

This should be the set up and I'll also explain why it seems the yellow is ground. Being it comes for the R/R routed to the stator the final end is the last coil to ground. If he runs any lights off the black and assumes the yellow is ground and uses it as such he'll eventually melt the system down.

This is/should be the set up.

Pink = hi beam
Black = 12Vdc from battery with key on
Yellow = R/R input DC
blue/white = lo beam
brown = side running and/or tail lights also could be instrument lights

It's possible the pink and blue/white could be opposite as pink = lo beam but I doubt it.

So why the black 12Vdc feed if you run the lights off of the stator/R/R when running? Black = what the Chinese call passing light and the switch should go to this part or even have a separate little spring loaded switch that when pressed sends 12Vdc to the hi beam only. The theory is brighten you light so someone can see it and know you are going to pass them.

The lo beam = blue/white should come on with the scooter running and stay on in both positions, lo only and lo/hi together, only the hi beam goes off when the switch is moved to the lo beam position.

The yellow should be placed on the switch so that when the scooter starts you should have a lo beam and tail lights along with other lights fed by the brown wire. Then the yellow have a little jumper that puts it on the hi beam part of the switch opposite the pink wire.

The black will go to the part of the switch that is the passing part and then feed a little jumper that should tie in to the pink.

JR

[fj12rider]

Thanks mate that makes better sense I'll re wire it tomorrow . Using the above , to be honest if I can't get it working like that then I'll just go back to what I have above as it all works and with the engine running it shouldn't kill the battery , but will try and get it right . Any chance you could let me have a little diagram to shout me how if wire that please . The internal of the switch has 2 diagonal jumpers they go to the top 2 rows as shown in my pic, and the one along the bottom jumps two at a time horizontally if that makes sense .

Cheers for your helps guys.
Dave


edit : after reading your post again , there is no pass button on the scooter , I know what you mean though as I have one on my yammy fj1200 , pressing it gives you hi and lo on at the same time, but like I say , the is no pass button on the scooter , the light switch is , off / side lights / main lights according to the symbols .  I think I'll stick with what I have , except I'll swap to using the yellow feed for the head/tail lights . I have no idea about the pink still , will run the bike tomorrow and check the voltage . Pink def isn't high beam , if I put power to it nothing lights . The blue /white is the feed to the hi/lo beam switch for sure .

thanks again . 

[fj12rider]

Just a quick update , it appears that there is no voltage from the yellow or pink wires with the bike running , the pink is coming from a ballast resistor , so I assume there should be voltage coming from there , I will check that today to see if there is power going into the resistor , if not , the charging circuit is working ok so I'll just leave it as it is run the lights direct from the ignition and see if it flattens the battery , it shouldn't do if the bike is running.

ive narrowed the black down to brake light feed , it's all a bit , well Chinese really . Lol

[rob63]

It`s a confusing one, it seems as if your system is designed so that DC voltage from the battery powers sidelights, horn etc. and the headlight would be powered by AC through the yellow wire. However as there is no voltage through the yellow wire that seems odd. The pink wire to the ballast resistor won`t have voltage coming from it, only to it. it`s there to take away unregulated voltage from the yellow stator wire and dissipate it in the form of heat into the atmosphere. The unregulated voltage would otherwise cause a few blown bulbs.
If you are happy with your current DC set up and everything is working, then as long as you have at least 13.5-14.5 volts at the battery when the scoot is running, then it shouldn`t necessarily go flat with proper use.

[fj12rider]

Eureka . I now have voltage from the yellow wire, the lighting circuit on the stator was faulty . I've replaced the stator with one from a yammy , and not I have voltage from the yellow. Can you tell me what to do with the the pink to stop bulbs blowing please mate , do I just join it to the yellow ? 

[rob63]

I`ve got a feeling that you connect the pink into the off/side/head switch so that when the switch is off the voltage from the yellow has somewhere to go. A simpler option is to splice the pink wire directly into the yellow before it gets to the switch and it`ll do the same job.