Need a little wiring help - Pocket Bike Forum - Mini Bikes
Reply
 
LinkBack Thread Tools
post #1 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Need a little wiring help

Hi all. Trying to get some of this rats nest, errrr I mean wiring figured out. I have the headlight working and some lights come on in the speedo. My current question is the back blinkers. I have 5 wires. The brown appears to be ground and goes to both lights. The yellow on one side and orange on the other I think are the positives. The blue and green go to the middle light. Is the middle light a brake light?
Attached Images
File Type: jpg 53447654-5466-4168-89EE-C037B78E0F9C_1554295871121.jpg (341.0 KB, 9 views)
File Type: jpg 5B4AF4EA-A4FF-447F-830B-7F59DCCE7DB5_1554295892542.jpg (327.5 KB, 10 views)
File Type: jpg BD1B2965-7A20-44F6-B59B-63BEE4302F32_1554295911754.jpg (433.5 KB, 8 views)
File Type: jpg 2BD0480F-3AFE-413D-8746-DBC7E9993934_1554295934059.jpg (333.4 KB, 10 views)
markek is offline  
Sponsored Links
Advertisement
 
post #2 of 57 (permalink) Old 04-03-2019
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Having a Digital Multimeter is the perfect tool for this job as you can trace power and do continuity tests to verify which wires have power and which have a ground point.....


Running light with brakelight together has a two filament bulb with 3 wires...If yours is only 2 wire its gonna be a running light only....

Green to green...

Blue to blue

Red to orange

yellow to brown

brown to black




Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 11:52 AM.
CAM2 is offline  
post #3 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Thanks Cam. Although not great at it I did use a meter. For instance on the left blinker and using wires brown to black and yellow to blue there was no voltage. With the blinker on I get voltage.

The back light has only two wires (green and blue). Do either of these get connected to the black ground?
markek is offline  
Sponsored Links
Advertisement
 
post #4 of 57 (permalink) Old 04-03-2019
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Quote:
Originally Posted by markek View Post
Thanks Cam. Although not great at it I did use a meter. For instance on the left blinker and using wires brown to black and yellow to blue there was no voltage. With the blinker on I get voltage.

The back light has only two wires (green and blue). Do either of these get connected to the black ground?

Usually the green wire is the ground...…..

Look at meter #1 in the pics I supplied...That's continuity test mode setting...

Put your meter on that setting...ground the black probe to the battery and touch the green wire with the red wire...If you hear an audible beep that means you completed the circuit and that would be your ground wire...

Next check the black wire..It could be a ground wire aswell..

Check all wires to see the deal...If you get more than 2 beeps on 2 different wires you have a wiring problem...

Put the multimeter on 12v setting now.....

Turn on the left blinker..touch the red on each of the remaining wires til you get a reading .........That would be your left turn signal power..

Do the same for the right turn signal then your running light.......

Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 11:39 AM.
CAM2 is offline  
post #5 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Wouldn’t the brown that comes from both blinkers be the ground and be connected to the black?
markek is offline  
post #6 of 57 (permalink) Old 04-03-2019
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Quote:
Originally Posted by markek View Post
Wouldn’t the brown that comes from both blinkers be the ground and be connected to the black?
Brown coming from the blinkers does logically seem to be the blinker grounds.

Take your multimeter and do a continuity test on both green and the black wire with the keyswitch off...If they both beep theyre both ground wires..If not find the two that do beep...…...They'll be your dedicated and seperated grounds...

Usually you want to separate the blinker grounds fron the running light to prevent feedback which would cause the taillight and the headlight to pulse as the blinker lights blink as after all youre dealing with a floating ground wiring system..

This is how to properly wire-in a blinkr system on a motorbike..Notice the lack of headlight and taillight...Theyre their own seperated system.


Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 12:12 PM.
CAM2 is offline  
post #7 of 57 (permalink) Old 04-03-2019
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Its really easy on some bikes to totally strip everything handles and all then hook it up to a SLA battery to power it up just as it would be on the bike to test where the problems are then fix those problems with solder and shrink sleeving,,,....

On this X1 harness some member bought it from me when I converted my X1 to parkinglot racer...He paid me extra to make the harness as close to the real deal motorcycles aswell as replace all conventional bulbs with LEDS...

Laid out and fully functional with a connected battery they basically look like this in a nutshell...…..


Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 12:33 PM.
CAM2 is offline  
post #8 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Re: Need a little wiring help

Here's what I THINK I have!

Battery black to black wire - continuity
Battery black to brown wire - continuity

Key on - no blinker
black to green 0
black to blue 0
black to red 0
black to brown 11.88V

Right blinker on
black to green 7.68V

Left blinker on
black to blue 7.68V

Brown to all wires are a negative reading

Blinker bulbs work when connected directly to battery so i know they work. When wired to mini chopper wiring they will not light.
Bulbs are 10W bulbs - may be the problem?
Ordered new blinker relay - possibly the problem?
markek is offline  
post #9 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Re: Need a little wiring help

I did get the one blinker bulb to flash at one point. Probably about 4 fuses ago!!
markek is offline  
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Quote:
Originally Posted by markek View Post
Here's what I THINK I have!

Battery black to black wire - continuity
Battery black to brown wire - continuity

Key on - no blinker
black to green 0
black to blue 0
black to red 0
black to brown 11.88V

Right blinker on
black to green 7.68V

Left blinker on
black to blue 7.68V

Brown to all wires are a negative reading

Blinker bulbs work when connected directly to battery so i know they work. When wired to mini chopper wiring they will not light.
Bulbs are 10W bulbs - may be the problem?
Ordered new blinker relay - possibly the problem?
So the black and brown are negatives coming from the harness and what the chinese use as a ground is showing power along with one known to not be a ground.....

Thats a good thing to know and an obvious sign of a problem...


I would remove the whole harness with keyswitch/handlebar switch and untape the harness but you can try looking towards the charging port and keyswitch areas for obvious signs of trouble......


Only other thing I can think of is asking you how the keyswitch is wired....There should be two solid orange wires or two solid yellow or pink wires on one plug and a second plug with a black with white stripe along with solid green called the flameout....

The oranges go together to transfer the juice and the black /white wire with solid green wire are the killswitch wires...black/whire is pulse power,green is ground..

One orange comes from the fuse which is between the keyswitch and the battery into the other orange wire to transfer battery power to the starter solenoid and the rectifier..


Ground[green] or pulse power from the coil [black with white stripe]should never interfere or intermingle with the two solid same color power wires at the keyswitch....

ON position on the keyswitch connects the two solid power wires...Turning the key OFF disconnects power and enacts the killswitch…..

The yellow wire coming from the rectifier box should have a terminal lug and be on one terminal of the solenoid going to the generator/starter.

The negative on the battery connects to the frame and the frame should be free of paint.....The harness grounds to a lug on the engine case which is also grounded free of paint to the frame......

Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 05:47 PM.
CAM2 is offline  
post #11 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Re: Need a little wiring help

Thanks Cam.

I did wire in a new keyswitch awhile ago. I will check that and post a pic.

I'm thinking somewhere down the line this points to USER error (me)!
markek is offline  
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Quote:
Originally Posted by markek View Post
Thanks Cam.

I did wire in a new keyswitch awhile ago. I will check that and post a pic.

I'm thinking somewhere down the line this points to USER error (me)!
The chinese are crafty...They use the same color wires both ways and create so much confusion its ridiculous...Its mostly due to importing rules....


Lost try bypassing the safety interlocks where you have to squeeze the rear brake handle to get it to e-start and they try wiring in a brakelight then they lose the key and twist all the wires together to hotwire it which shorts almost everything out in a flash..........Light bulbs included aswell as sometimes the coil.....

Im gonna look for my wiring diagrams and if you can do the intital wiring and charging system working you cab then add in on a asperate fuse the headlight/taillight then the blinkers and not be as hard or problematic as you see...........


It will be quick and youll also have firsthand knowledge on how everything works and is routed....

Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 05:47 PM.
CAM2 is offline  
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help



On this diagram you can splice the blinkers after the keyswitch and you can also use a 7.5 amp fuse to extra protect the 10 amp fused wiring before the keyswitch..



On this schematic you can also splice the gauges/handlebar switch into it after the fuse..Just omit the battery and splice it after the keyswitch aswell with another 7.5 amp fuse to extra protect that circuit..


Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 06:32 PM.
CAM2 is offline  
post #14 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
I think I’m close, most everything appears to work. If I’m getting only around 8v to my blinker bulbs and my blinker bulbs are 10v do I have the wrong bulbs?
markek is offline  
post #15 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
My switch wires
Attached Images
File Type: jpg 62B7FAE2-98B7-465F-9A33-F5A08E758062_1554332514832.jpg (291.8 KB, 9 views)
markek is offline  
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Quote:
Originally Posted by markek View Post
I think I’m close, most everything appears to work. If I’m getting only around 8v to my blinker bulbs and my blinker bulbs are 10v do I have the wrong bulbs?
Your bulbs are 12volts 5 and 10 watts......Look at the blinker beepie box

Try bypassing the beepie box by unhooking the beepie box and hooking both wires together then measuring voltage again...The bulbs will be solidly lit.

If the voltage increases the beepie box is the draw..a 2 pole regular duty GM flasher ballast from an early model 80's car will work...

If it doesnt correct its most likely the handlebarswitch internal switch thongs..Theyre made of tin.......They can be disassembled and cleaned up..just be careful of the lil spring...……...

Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 06:46 PM.
CAM2 is offline  
post #17 of 57 (permalink) Old 04-03-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Re: Need a little wiring help

I have a new blinker relay coming in Friday. I suspect that might be at the very least part of the problem.

Cam, checked your profile you have some collection there!!
markek is offline  
BUILDEM,WRECKEM,REBUILDEM
 
CAM2's Avatar
 
Join Date: Mar 2008
Posts: 21,049
Re: Need a little wiring help

Quote:
Originally Posted by markek View Post
I have a new blinker relay coming in Friday. I suspect that might be at the very least part of the problem.

Cam, checked your profile you have some collection there!!
Thanks....Theyre a labor of loving what makes me happy being able to make them better than they was before or create something new or different..

One day ill add another album.Theres a few more....Maybe a lil later on...LOL

Cut
Up
Stuff
To
Obtain
Masterpiece

Last edited by CAM2; 04-03-2019 at 10:02 PM.
CAM2 is offline  
post #19 of 57 (permalink) Old 04-04-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Re: Need a little wiring help

Made some progress today. Put in a new blinker relay and still couldn't get blinkers to work. I then bypassed the wiring to the back of the bike and wired directly to the blinker bulb itself and it worked! Looks like I have some bad wiring to the back that I need to replace.

My problem now is that in addition to the back blinkers I have a bulb in the middle that I am assuming is a brake light that I can't get to work. There are two wires coming from this middle light, a blue and a green. This is what I know so far.

Red from the harness (along with the black) gives me 12v when the brake is applied. The Yellow from the harness seems to be 12v when the key is turned on.

So basically I have two extra wires from the back lights wiring harness. A red and a yellow and two wires coming from the light, a blue and a green.
Attached Images
File Type: jpg back light.jpg (480.1 KB, 6 views)
markek is offline  
post #20 of 57 (permalink) Old 04-04-2019 Thread Starter
PBP RACER
 
Join Date: Aug 2010
Posts: 80
Images: 1
Re: Need a little wiring help

After thinking about it I just realized that I would have to have a third wire (ground) going to the brake/tail light. I must be missing it or it came off. Back to the drawing board!

Time to invest in some new back lights with the harness.
markek is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Pocket Bike Forum - Mini Bikes forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Pocketbike Forums Replies Last Post
help I need an idiots guide wiring and I need to know what it is thanks screemers3 New to PocketBikePlanet? Start Here With an Introduction. 4 09-20-2014 05:38 PM
Im new and need a little help Peasnall Air Cooled Pocketbikes 1 06-07-2005 04:50 AM
walbro 603 carb results need a little help gixxer50 2Stroke Midbikes 7 10-29-2004 08:37 PM
need a little help.. asnboi512 2Stroke Midbikes 1 10-22-2004 06:23 PM
GRC GP owners i need a little help here loco007 European Pocketbikes 4 09-05-2004 10:13 AM

Posting Rules  
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome