Low beam won't come on

[scootnewb]

Hello,

My low beam doesn't come on. Also my ignition switch doesn't light anything until it is all the way to on. IIRC it would light the cluster and lights etc etc on one position counter clockwise from fully on.

I know this is for scooters but the wiring harness and most electrical in my bike is like a Tao Tao scooter. CDI, stator, voltage regulator. 

The bike had this problem then mysteriously went away. Now it's back. I've tried 2 different clusters, 3 bulbs, another CDI, and voltage regulator. I bridged the connectors on the light switch thinking it may be the switch but no go. I've ordered another right hand controller and an entire wiring harness but really, I'm just grasping at straws. 



The right hand control has an on and off switch for the lights, the left hand has a high beam switch and a high beam flasher. The hi beam flasher works with the light switch either on or off. The hi beam switch doesn't work at all. 

Any suggestions on what and how to check different things to check

 

[jackrides]

You need a wiring diagram. If you don't have your exact one, a Tao Tao (more on that later) Thunder one is probably the same thing. Left side of this page; Directory; W; Wiring Diagrams; Tao Tao Thunder.
You'll see that the headlite is powered directly from the stator (with the same wire also going to the regulator). The number of connections is very small. Grounds are the most typical demon in basic vehicle wiring. Run an independent ground wire from the headlite bulb(s) to the engine case and/or battery ground. Demon banished. It may find another place to live, but there are less possibilities. Most likely is a bad connection; could be the stator.
Now, as promised, a discussion of Tao Tao, mahi mahi and other such language absurdities. I went into a local restaurant and asked about the evenings specials. Was told marinated grilled mahi mahi. I responded 'I'm really not that hungry, one mahi would be fine'. After thinking about it the server told me that a mahi mahi is a fish. (duh) Why not call it a mahi or a dolphinfish (so people don't think it is Flipper). Same with Tao Tao. I can only ride one at a time. I have a Tao and I am quite happy with it. Anyone know how this word repetitive waste of time (like this rant) started?

[scootnewb]

Thanks. So the Stator can cause it even if the bike is not running? I have a spare stator for the motor.

[GrumpyUnk]

If the high beam works with the 'flash' switch, then power is getting to the switch. You must determine if that is the same power source(likely) that the high and low beams use normally. If so, the switch or internal connections could be damaged. I have seen them disclose piles of rust internally, able to switch nothing, if they have been exposed to rain for any length of time. You could take the switch from the handle bar and disassemble it, or check that it will pass power(VOM to the wires, one to power, other to HI or LO out as desired). Real test would be appling voltage to the input, and a grounded light wire to the output.
Most are operated by the less regulated current produced by the stator with the engine running. Many have the cluster bulbs also powered by that source, not battery voltage.
Turn and brake lights should operate on 12V battery voltage in most. Headlights and running lights not so much.
tom

[scootnewb]

Thanks all.

I figured it out. It took a new wiring harness to realize there was a bad wire on the left hand control. The Hellcat is a weird one. It has a light on off switch on the right side control. There is a wire that goes from the right control to a wire coming from the left control neither is part of the terminal connection.

Also if your cluster lights N and 4 at the same time and you blow a fuse when you put it into gear, that means you reversed the connections for the gear indicator sensor and the voltage regulator.