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Post by leo on Aug 1, 2011 21:20:54 GMT -5
well, i've finally bit the bullet and decided it was time to rewire my bike.
went outside and spent maybe 15 minutes on it and decided it was just too frakken hot so i wheeled the scoot into my apartment, hope the manager doesn't mind.
got the side panels off and disconnected everything that had a plug or connector.
got to the front of the bike and noticed about 100 wires that are totally useless.
well i'm committed, there is no turning back now.
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Post by catrell92 on Aug 1, 2011 21:23:50 GMT -5
i have the same scoot as you, please make frquent updates and let us know if any performance/reliability was gained from rewiring other than getting the china crap out, could be made of twizzlers which is highly questionable
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Post by smokindawg on Aug 1, 2011 23:42:30 GMT -5
I just got done doing some wiring on mine. I found that there were no breakers on my scoot other than the one on top of the starter solenoid. I wired in a couple 20 amp breakers and also hooked up 4 relays which run power for most of the items.
I found that most the grounds and the hot wires for items are all connected together and that they are connected using a much too small wire. I seperated several of them and ran them thru the relays and added bigger hot wires. I also seperated several of the grounds and hooked them directly to the frame. It helped on mine as I now have the charging system working. (It wasn't before I started)
Good luck with your re-wiring. I'm glad mine is over and I can now actually ride the scooter for a change.
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Post by leo on Aug 2, 2011 4:01:47 GMT -5
got the harness off he bike.
actually there are two of them.
one has the tail light, brake light, rear turn signals, license light, CDI, regulator/ rectifier, and the choke wires.
the other one was the one in the front and had all of the wires, about 15 or 20, that went to the dash, headlights, front fan, horn, and god knows what else.
i pitched the front harness in the trash.
i peeled the ribbed housing off he rear harness so i could trace each wire and do an ohmmeter check of it. i'm glad i did because there are some wires that "change color" inside the housing.
i also found where the "short" was.
right where the harness makes the turn from the bottom of the bike going up into the nose.
the harness in this area was pinched almost flat.
since i didn't mark anything putting this thing back together will be interesting.
my ignition switch is shot, i plan on replacing it with a double pole double throw switch.
i also plan on bypassing the brake switch in the start circuit and use only the push button.
i can't use any of the original switches because they have fell apart long ago.
i have noticed to my utter surprise that there was only one ground on my bike and it was the size of my red starter wire and connected to the starter mounting screw.
well, finding a schematic for my bike was IMPOSSIBLE, the best i could do was to piece together what looked right and made sense.
i also noticed that the rear brake line is routed OVER the frame on the bottom. thank god it's armored or it would have failed due to my feet pressing it against the frame. simple to fix though, remove the master cylinder and reroute. no sweat on that.
it's kind of strange to see my scoot sitting in the living room naked.
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Post by leo on Aug 6, 2011 17:04:14 GMT -5
got the old harness all scoped out.
after removing the wires for the stop/tail light and turn signals i find i have:
start wire, red/white, goes to the start button.
CDI pulse wire, also red/white, gets grounded to kill the bike.
positive from battery, red, fused.
black, switched (+) DC power.
green, ground. the frame of my bike is not used for ground.
the choke is ran off of one of the stator yellow wires.
there are 3 wires in the choke bundle.
one is the ground for the choke.
one is hot for the choke and connects to one of the stator wires.
the other one is the wire for the temp gauge.
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Post by friedshrimp on Aug 7, 2011 6:55:35 GMT -5
Since you're ripping yours apart, do you know where the fused wire that connects to the + side of the battery runs to up front? I believe it has changed colors along the way as well. Trying to get plastics off but it's so damn hot here in Florida, even in the shade. This is the wire that if the fuse blows, there is no power, no where. Thanks for any input you can provide.
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Post by leo on Aug 7, 2011 8:18:03 GMT -5
the wire you refer to goes to the R/R and the ignition switch
yes, blowing the fuse will prevent all power from getting to your bike.
there is a black wire that also goes to the ignition switch.
the black wire supplies power to the bike with the switch "on".
the black wire should be the one you connect all of your stuff to, lights, horn, etc.
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Post by leo on Aug 9, 2011 17:21:11 GMT -5
well i got it all done and took it for a spin.
noticed a problem though, not related to the work i did.
the bike sat all winter and up until a few days ago with gas in it.
i think this stale gas screwed up my carb, specifically the slow jet.
the bike stumbles and hesitates from standstill to about 10 MPH, sometimes it won't get above about 15 MPH.
a new carb might be in order.
i took my old one apart and remove the slow jet and cleaned it with a strand of copper wire.
does this jet have a hole that goes from end to end? mine doesn't.
mine has 4 holes drilled through the jet from side to side.
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Post by smokindawg on Aug 10, 2011 7:45:28 GMT -5
My scooter sat for almost a year too. I got it to start but it did as you said. I took the carb apart and cleaned it with carb cleaner and blew it out with air.
It now runs good and idles perfect. I did however find that I need to rejet it as top end isn't great and it appears to be running too lean. I'm now waiting on the main jets I ordered.
As for the idle jet, yours sounds correct.
I'd remove both jets and also make sure and clean all the passages good with the carb cleaner. Just watch the rubber parts as the cleaner will eat them up quickly and ruin them.
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Post by leo on Aug 10, 2011 17:05:06 GMT -5
took the carb off today and the first thing i did was blow into the hose that comes off the manifold.
a piece of garbage the size of a pea shot out of the front of the carb.
i have a uni filter and apparently a piece broke off and lodged somewhere inside the carb.
anyway she runs great now, and the battery will hold a charge.
looking really good.
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Post by jonathan150cc on Aug 11, 2011 13:40:36 GMT -5
A piece of the UNI foam material broke loose? Make sure you have that thing oiled. And if it's starting to crumble like that, you'd best replace it.
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Post by leo on Aug 11, 2011 13:52:19 GMT -5
A piece of the UNI foam material broke loose? Make sure you have that thing oiled. And if it's starting to crumble like that, you'd best replace it. it's the only explanation, i never ride my bike without the filter. it was on the bike when i got it in january 2008. yeah, i keep it oiled, i was using a spray type filter oil but i quit using it. now i use straight 10-W40 engine oil. |
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Post by leo on Sept 10, 2011 4:15:12 GMT -5
well this is the third time i've had my carb off trying to figure this thing out.
i replaced the autochoke and it helped some but the low end bog is still there.
got a really bright light and a good magnifying glass and started to work.
found 2 problems.
1. slow jet completely plugged. got a bread tie and cleaned it out.
2. diaphragm needle had a "bur" on it causing it to hang in the main jet.
well got the carb back together and waiting for daylight.
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