Piaggio Zip 2t 50cc - Rewiring Key Switch / Ignition

[cockyboy]

Hi

I've just inherited a 2014 Piaggio Zip 50cc scooter from a mate. He had it stolen from him earlier this year and the police recovered it. The thief had damaged the ignition before cutting the wiring behind the key switch and hotwiring it. The local repairer replaced the barrel in the ignition but then couldn't work out what to do next and gave up. My mate in turn gave up and gave it to me as a project, which would be great if I had any idea what I was doing. From what I've been able to find on the interwebs, the Piaggio wiring harness is all in one piece, unlike the Chinese ones where you have regular connectors. The rest of the wiring is good so I don't want replace the whole thing. The front of the ignition barrel is now rekeyed, but the back is empty (see photo). I think this is where the key switch goes, and I'm guessing there would normally be a clip on the harness that attaches to the key switch. I could be way off though. Attached are pics of the side view of the barrel, the rear off the ignition barrel where i think the key switch should go, and the wiring that was cut that looks like it had been in the back of the ignition barrel / key switch. Wire colours are 2 x white, 1 black, 1 red/white, 1 green. My guess would be I buy a new key switch and then rewire it by splicing extra wires where others are cut? Or find a bike at the being wrecked (easier said than done) and cut the ignition wiring. Any help would be appreciated. 

[spaz12]

Looks just like the Vespa et2 ignition.
Anyway, your best bet is to look on ebay for a whole new wiring loom. They're usually not all that expensive and not too hard to install.
Finding the short piece that has been cut off will be extremely difficult since it's unlikely someone would sell just that and not the whole loom.

[spaz12]

m.ebay.com/sch/i.html?_from=R40&_trksid=p2056088.m570.l1313.TR3.TRC0.A0.H0.XWiring+loom.TRS0&_nkw=Wiring+loom+Piaggio+zip

[spaz12]

I could be wrong, but it looks like the clip that holds the back part of the ignition barrel is missing. I think this is the right one:
www.pedparts.co.uk/product/3390/ignition-steering-lock-barrel-clip--piaggio

[geoffh]

cockyboy,there is a wiring diagram of a piaggio ignition in the manuals section(click on left of screen)I,m no expert but a quick look says the colours out of the switch change at the first plug,orange to green etc might be why it,s so hard to figure out.Also had a quick look on ebay the back of the switch is just a plastic section with connections,i searched piaggio ignition(and havn,t a scoobi how to post a link) 
geoff

[spaz12]

Just found the piece that you need, but you'll have to figure out the wiring.

www.pedparts.co.uk/product/456/piaggio-ignition-lock-switch

[cockyboy]

Thanks Geoff and Spaz - looks like I was on the right track. Might see if I can find a harness at a local wreckers, otherwise I’ll hit up eBay. Will let you know how it goes.

[cockyboy]

Dec 5, 2017 16:24:16 GMT -5 spaz12 said:

Just found the piece that you need, but you'll have to figure out the wiring.

www.pedparts.co.uk/product/456/piaggio-ignition-lock-switch

It looks like the wiring will reach the back of the ignition so I’m guessing it was simply yanked out. Do you think it would be possible to attach flat clips to the wires and then work out which goes where on the ignition lock switch (that you suggested) by trial and error?

[spaz12]

Dec 5, 2017 17:33:10 GMT -5 cockyboy said:

Dec 5, 2017 16:24:16 GMT -5 spaz12 said:

Just found the piece that you need, but you'll have to figure out the wiring.

www.pedparts.co.uk/product/456/piaggio-ignition-lock-switch

It looks like the wiring will reach the back of the ignition so I’m guessing it was simply yanked out. Do you think it would be possible to attach flat clips to the wires and then work out which goes where on the ignition lock switch (that you suggested) by trial and error?

Sure, you could use the blade clips, but I wouldn't do the trial and error trick trying to figure out what goes where. Look in the MANUALS section like Jeoff suggested so that you're sure. You don't want to burn up the loom or ignition switch or even the ignition itself.

[cockyboy]

Thanks for the help so far - I managed to track down a wiring harness and keyswitch from a scooter wrecker in Sydney. I cut off the wiring and clip that goes into the keyswitch and joined it to my damaged wiring with buttsplice crimps and it looks like it worked! Turning the key gets the dash lights on and the start button gets her cranking, but won't fire. I also tried to kick start it but no good either. She's juiced up so my next move will be to pull out the spark plug and make sure that is OK. Then I guess move on to carby / fuel delivery. Should be a pro by the time I get her going.

[geoffh]

Must be nice there,most of us are sat freezing are bats off and you get to swan around in shorts .Check the directory for Brents non starter guide and keep us posted.

geoff