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Post by rocman5190 on Apr 1, 2019 14:01:44 GMT -5
Hey so I am new to scooters. But have been fixing many things for a very long time. My problem is the scooter is brand new to miles. I got it cheap because no power guy says. I found fuse blown. And keeps blowing. If I disconnect the ignition switch the fuse stops blowing trying to test the ignition switch the red power wire and the black have continuity with the key on. I don’t think that is right. There is a red wire a black with a white black and two greens.
Seems that the power has been grounded inside the ignition switch. Anyone have any insight on this problem. I would appreciate it greatly. Thank you
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Post by 90GTVert on Apr 1, 2019 14:31:13 GMT -5
 Does the fuse blow with the ignition switch on or off? Asking because if it only blows when the key is on, it could be something else that get's ignition switched power. It could also be too low of a fuse rating (check the owner's manual). If it's blowing with the key off and then stops when the ignition switch is disconnected, then it sounds like the switch is the issue. Red and black may be normal. I know a lot of us think of black as ground, and it is ground on some scooters or in some spots in the wiring of scoots, but not always. Some ignition switches use black as part of the ign switched power circuit, usually the ign switched power with red being batt +. In that case, those 2 should have continuity when the key is on and none when off. Green is very often ground. You should find another circuit that has continuity when off and none when on, and that is the kill circuit that sends a ground to the CDI to stop the engine. Check for continuity from the red or black wire to either a ground wire or the metal casing of the ign switch while it's unplugged. If either of those has continuity at any point it is shorting.
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Post by rocman5190 on Apr 1, 2019 14:50:39 GMT -5
Thank you very much for replying. So the black wire has continuity to ground. If i unplug key switch it stops blowing. Its the glass 10a fuse.
type.
The hot wire comes up to the switch. And comes out pn the black grounded wire hench popping the fuse. So me trying to diagnos this it got me thinking the ign key switch is defective. I wish i found ghe correct witing schematic. I wonder if i keep looking on here i will find.
I understand sometimes wire colors change. Im not the best at diagnosing but all leads back to the power being grounded popping fuse..
im open to and help.. thanks
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Post by 90GTVert on Apr 1, 2019 15:38:40 GMT -5
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Post by snaker on Apr 1, 2019 17:02:32 GMT -5
Oh you lucky dog. A direct short to ground is the most fun electrical problem to have. OK maybe a bit of an exaggeration.
It helps a lot to make a organized and logical plan. Try not to go in and start shaking and wiggling the wires. A intermittent short can go away and then come back at a worst time.
If you remove the fuse and connect a 12v test light across the fuse holder it will light up by using the short as its ground and go out when the short is removed. I have done a lot of this kind of troubleshooting through the years and made myself up a kit comprising a automotive type marker light and made connection adapters using several different types of blown fuses. I glued a magnet on the back of the marker light and hangers for convenience. Its way better than putting in and blowing piles of fuses.
With the test light in place carefully follow the circuit affected. Disconnect electrical connectors and watch for the light to go out. If it does than the short is on the fuse side of the connector, same with switches. Be sure to look the connectors over closely also. I've seen shorts where one connector pin had a wire strand touching another pin.
Even when your shaking down the wires try to leave all but the area your concentrating on unmolested. Example: hold one portion of a wire harness steady while you deal with another portion or hold the harness steady while you shake a connector. If your just yanking away at one spot and the light goes out you may think you found the spot when the short is actually in a different area that is getting jostled. I can't stress enough how frustrated it is when a intermittent short disappears and that you should do everything you can to prevent that.
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Post by rocman5190 on Apr 1, 2019 18:45:40 GMT -5
Hey thanks fpr all your ideas. Gonna go do some more checking tonight. Yeah so power into switch on fused red from battery. Next whrn key is turned power comes out of switch on black.
So maybe i asumed black was ground. But anyhow if its not the ground then its shorted to ground. That will be my next test. To find out where the black is going.
I did a continuity test on the black and its to ground so thats why im blowing fuse and assumed its a ground. Now i need to confirm its ground and internally switch is bad or. The black wire is actually shorted.
Thanks for all your help
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Post by SMALL CC TEK on Apr 1, 2019 20:31:28 GMT -5
Snaker and 90Gtvert , that is some valuable info you two just gave out !
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Post by rocman5190 on Apr 1, 2019 21:31:42 GMT -5
Snaker i used the testlight method. Tonight. Its got a dead short on black wire coming from switch. Red is feed for switch. And black n red have continuity thru the switch which is odd. Also the black has continuity to ground. So either its a ground wire or its shorted to ground. I have a new ign switch coming tmrw. I hope it fixes the short. I didcutthe black wire atswitch and short goes away.
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Post by rocman5190 on Apr 2, 2019 22:08:31 GMT -5
Fixed:::: so when I got home from work today I started removing body panels and unplugging anything with a black wire. Had no luck and thought I had disconnected everything. The one last plug that went to a center light over the front faring I unplugged and the short one away. I put everything back together. And all the electrical system is working correctly. It is a short harness with a plug and less socket with one of them push in 194 bulbs. I am going to try to figure out where the shorted socked is actually bad. Thank you everyone for all of your help. Read more: 49ccscoot.proboards.com/thread/24730/wiring-colors-particularly-black?page=1#ixzz5jzwQfmVE |
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Post by snaker on Apr 3, 2019 11:29:49 GMT -5
Great fix.
Do your self a favor. As you button up go over all that wiring and inspect closely. Look for wires rubbing or pulled tight around sharp corners. Get some of that spiral wrap and add as protection, even over the top of questionable existing wrap.
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