EN Help with fixing my bike:)

[lalalando]

Hello!
So my bike was stolen but luckily I found it. The problem is that was jump started and now it doesn't have any power at all.
the battery is at 12.7 V so I thought I might exclude it as the problem.
The main fuse is ok but one of the fuses under the saddle, to be exact the number 3, is broken.
I changed it and it broke again.
since the key switch was broken I bought one off Amazon with the same cables and changed it. The second fuse I put in blew after I turned the key. I then put in a 3rd one (same spot) but didn't turn the key: everything was fine.
I then reached to turn the key and just touching the cables in the headlight slot I heard the fuse blow again. Might there be a short circuit in the cabling? Or might it be a bigger problem? What next step do you suggest?

So I was wandering if something is missing in the connection shown in the attached picture. The location of which is behind the battery (removed in the picture)

Thanks in advance!

 

[Chemiepfuscher]

Hi @lalalando,
the plug you have there is for the diagnostic device, that's how it should be.

With your other problem there are only 3 possibilities.
1. Either your new ignition switch is broken (this can happen with cheap products made in China on Amazon)
2. You have wired something incorrectly (you can't always tell by the cable colors)
3. There is actually a short circuit somewhere else.

Based on your history, I would guess one of the first two points first.

 

[lalalando]

Thank you for the reply!
2. So the new switch fits directly into the "switch plug". It has 4 colored wires: red black green and white.

1.I checked and the resistance between the green cable and both the black and red cables and it shows that are open circuits however the switch is turned. Same goes for the white cable.
Meanwhile between red and black the resistance acts as an open circuit on Off, and is very little on ON. Viceversa goes for green and white.
I thought it was working, am I wrong? Or is it in a wrong order by accident?

3. There might be. Later I'll be able to check.

Should I worry it is something bigger?

I checked the circuit schematics a little bit and saw the blow fuse goes to the rectifier that then goes to a bunch of things. Any hints?

Can you tell me where to find the relays? I read in an older post that that might also be a problem

Thanks for the help, yep I'm a noob ahahah

 

[Bike Mike]

Hello!
So my bike was stolen but luckily I found it. The problem is that was jump started and now it doesn't have any power at all.
the battery is at 12.7 V so I thought I might exclude it as the problem.
The main fuse is ok but one of the fuses under the saddle, to be exact the number 3, is broken.
I changed it and it broke again.
since the key switch was broken I bought one off Amazon with the same cables and changed it. The second fuse I put in blew after I turned the key. I then put in a 3rd one (same spot) but didn't turn the key: everything was fine.
I then reached to turn the key and just touching the cables in the headlight slot I heard the fuse blow again. Might there be a short circuit in the cabling? Or might it be a bigger problem? What next step do you suggest?

The ignition lock was damaged when it was stolen ?!

The power cables connected when stolen?

 

[lalalando]

The ignition lock was damaged when it was stolen ?!

The power cables connected when stolen?

Anhang anzeigen 30795

The ignition block was broken yes, I guess with a screwdriver. The cables were cut to jump start it I guess but nothing seems missing. Except the USB charger ahah.
Thanks for the schematic!

 

[Chemiepfuscher]

Except the USB charger

...have you checked whether it has bare cables? This could also cause a short circuit if it was just cut off or even torn off.

 

[lalalando]

...have you checked whether it has bare cables? This could also cause a short circuit if it was just cut off or even torn off.

It has a socket And it seems to be fine.
I'll try to isolate the ending or remove it and isolate the cables

Ergänzung (15.12.2023)

If the problem is a broken cable in the electrical circuit, do you guys suggest to fix it (I eventually have a person for that) or should I replace the whole with a new or used one?

 

[Chemiepfuscher]

Repairing is almost always enough, as there is usually no need to install anything new if there is still enough material available. Simply put them together/connect them and insulate them well, something else a normal screwdriver workshop wouldn't do.

 

[lalalando]

Hello everyone!
Good news! The power is back! The problem was the key switch that had inverted cables!
however the bike doesn't start, not even the clicking of the starter motor and there's no tension drop on the battery when I push the ignition button.
Any suggestions?

 

[Chemiepfuscher]

Now that you have found the probable cause ( as already mentioned, with standard parts „made in China“ it is not uncommon for cables to happen…) first I would look at all the fuses again, not that you caught a final short circuit when replacing the cables.
If everything is OK, I would use a multimeter to check the cable to the starter button and the button itself to see if anything is being received there... if so, continue via the relay to the starter. There aren't many options left, either the cable is broken, the starter button doesn't make contact or there's no power coming to anything at all.

 

[guckie]

For next step i would check the starter- relais.
It hast 4 cables....two should be Red and and thick.., two should be thin.
Between the thin cables should be a tension of 12 V, when pressing Start- button
If you measure the thick cable contacts, one should have 12 V against frame
The other 0 V against frame. ( when Not operating the startbutton.
When operating Startbutton, both contacts ( thick cables) should have 12v against frame.

Edit:
@Chemiepfuscher was faster.

 

[lalalando]

Now that you have found the probable cause ( as already mentioned, with standard parts “made in China” it is not uncommon for cables to happen…) first I would look at all the fuses again, not that you caught a final short circuit when replacing the cables.
If everything is OK, I would use a multimeter to check the cable to the starter button and the button itself to see if anything is being received there... if so, continue via the relay to the starter. There aren't many options left, either the cable is broken, the starter button doesn't make contact or there's no power coming to anything at all.

Hi and thanks!
would you exclude the "no power coming to anything" knowing that the display, the headlights and the other lights work?

 

[Chemiepfuscher]

Electrics are not exactly my area of expertise, but since we have installed 3 fuses, it is possible that one part works (for example the lighting), but the other part does not (for example the fuel pump or ignition).
It occurs to me that when you turn the key to “on”, can you hear the fuel pump, or does nothing happen?

Maybe someone else like @Bike Mike or @guckie can help you with this question?

 

[guckie]

First: power switch (Key) "ON"
Then you should check all fuses as follows:
Fix the negative line of the Multimeter (or Testing- device) with a clamp at ground ( = frame).
With the positive connecting cable you test against both ends of the fuses...(therefore you need needle-formed / pointed testing probes).
If fuses (and fusebox) are OK, there should be 12 V at both ends of each fuse.

More i can't say....because i dont have a wiring diagram of the 125 ....sorry.
(And i am not a specialist / expert of the 125)

Testing connection-points of fuse: See picture below

 

[lalalando]

It started!!!
Thank you all a lot! Great forum and great people!

After the ignition block It was the starter button! It must have corroded a little because after a few "delicate" pushes I started hearing something so I kept pushing it more and more "gently" ahahah.
Time to ride again

 

[guckie]

Now I would open all switch housings and connectors and treat them with a good contact spray.
the best that I know of:

https://www.amazon.de/KONTAKT-CHEMI...t=&hvlocphy=1004445&hvtargid=pla-739406775760


This will reduce future electrical problems

 

[Fixbrix]

Now I would open all switch housings and connectors and treat them with a good contact spray.
the best that I know of:

https://www.amazon.de/KONTAKT-CHEMI...t=&hvlocphy=1004445&hvtargid=pla-739406775760


This will reduce future electrical problems

Contactspray can help,but to much are make this!Anhang anzeigen 30831

 

[elektrizikekswerk]

Contactspray can help,but to much are make this!

Please remove that gif. I'm no epileptic but even then it gives me headaches...
Thanks.

 

[Fixbrix]

Please remove that gif. I'm no epileptic but even then it gives me headaches...
Thanks.

OK its deleted.
Must not looking 10 hours on this Pic.

 

[Bike Mike]

Hello everyone!
Good news! The power is back! The problem was the key switch that had inverted cables!
however the bike doesn't start, not even the clicking of the starter motor and there's no tension drop on the battery when I push the ignition button.

when I push the ignition button

Starter button ?

Any suggestions?

For further information also take a look here

Brixton_WHB.pdf