Installing New 5-wire Ignition Switch - colors don't match!

[digitalrelay]

I bought a cheap replacement 5-wire ignition switch, and of course the wire colors and connector don't match. I've been trying to sort out what's what so I can use it anyway. I'm hoping someone can confirm or advise on how to make this work, or let me know I'm wasting my time.

I've use my multi-meter to determine which wires connect when in run or off. Here's what I've deduced:

2002 TNG Venice
Old switch:
1. Red - battery
2. Red white - ignition on power when run
3. Gray - connects to black, black white when off (CDI?)
4. Black - connects to black white and gray when off, not connected when run
5. Black white - connects to black and gray when off, not connected when run 

New switch:
1. Red - battery
2. Black - ignition on power when run
3. Black white - connects to both green when off (CDI?)
4. Green 1 - always connects to Green 2, connects to black white when off
5. Green 2 - always connects to Green 1, connects to black white when off

So I think I have it mostly matched up, but the New switch having both greens connected at all times is different than the old switch.

Am I good to go swapping out as noted above? Any insight on how to make it work, if I can?

[digitalrelay]

I decided to give it a shot swapping wires as noted above. The starter would spin, but the engine would not fire. Seemed like a spark issue, so I disconnected the Old Black White/New Green. The engine fired right up, all accessories worked. I turned the key to Off, and everything shut down as expected.

I then put my multimeter on the battery to make sure it was getting charged while running. It read 13.0v when off. I started and it went to 13.2v at idle. Revving the engine brought it to around 14.3v, so I called it good.

The new switch was physically different than the old, so I had to drill an additional hole on the mounting tab to allow for a small nub on the switch. That helped align it. I also drilled the mounting hole in the switch a little bigger to give some margin. I was able to orient the new switch like the old one was, but only one mounting screw was going to be useable. I got it all installed and ran a zip tie to help hold the switch tight and keep it from turning.

So, it's all working and looks stock!

The New lock I got was a cheap eBay deal for ignition switch, locking gas cap, and seat lock for $15. Amazon had what looked like a direct replacement for my scooter for about $35. If I was doing this over again, I would have spent the extra money and got the direct replacement. It'd be nice to have a matching lock set for everything, and I would not have had to spend so much time modifying to make everything work. On the bright side, I saved $20 and learned a little more.

[ThaiGyro]

Good for you! The lack of response was due to the issues you outlined so well. Hard to offer valuable advise on this one.

You did all the right things it appears. It is not always apparent.

Many, many years ago, I worked in a building in San Francisco. I was 19-20, now NOT. We had problems getting our backup chiller running. I was OK with the mechanical side, but found issues with the wiring, which was not my forte' then.

We hired a reputable A/C firm, who sent us Bruce, the wonder man. I worked side-by-side with him for a few days to learn. Effectively his dumb assistant. Reading the schematics, we both became frustrated. Bruce would be focused on something...and ask me "What color is the wire marked xx?" RED. What about the wire marked nn?" RED. He would come and test continuity, or set a small voltage and check and check and check.

After two days of that shite, Bruce looked at me and said "I cannot figure this out!" That day we discovered two big problems: First, the wiring had been done wrong and the "doer" used all red wires, probably in haste.

Secondly...BRUCE was color blind!

We ripped out all non code wiring and started from near scratch. Two days later had a great running chiller. The wiring was the only problem. Bruce was not only a magician, but had the best Norton 850  I ever rode!