Help wire Li 150

[Souly50]

Hi

Can anybody help please I have a Li 150, 12 volt, non battery and I am trying to wire it up and every time I think I have it right I can not get any of the lights to work it starts great but no lights. The CDI & the regulator must be right for it to start and there were wiring instructions with them so easy to follow but none with the harness, ignition switch & handlebar switch. Here is a breakdown of the wires:-

Harness wires Ignition Switch Handlebar Switch
1 x Black 1 x Brown 1 x White
1 x Green 1 x Green 1 x Brown
1 x Brown 1 x pink 1 x Red
1 x White 1 x Orange 1 x Blue
1 x Pink 1 x Black 1 x Purple
1 x Blue 1 x Black
1 x Yellow 1 x Yellow

I have wired the following:-

Rear light – Black from CDI (Earth), Black & Pink from Harness.
Rear brake switch – Pink & White from Harness
Horn – White & Brown from Handlebar Switch

Now I am at the Main Bulb holder/Junction and I have tried different combinations but nothing seems to work.

The bulb holder is the Grey type which is used on later CEV type which has the following connection points:-
At the top is white and yellow connection
Next are 3 connections for blue and the other side 3 black
Next 2 brown connection and the other side 2 pink
Bottom is 2 orange and opposite is 2 Green

I have tried doing the obvious i.e. put the same colours together on the same colour connections but as I say nothing no lights no horn. I appreciate it is hard to say without seeing but any help would be appreciated.

Stuart

[missing lynx]

you don't mention earths in the headset but without seeing how you've connected things up it's hard to say. is it a new loom? have you got stickys book to look at the wiring diagrams have you checked power is coming from the regulator the easiest way to do this is to a 12v bulb take the brown wire from the loom touch the bottom terminal of the bulb the earth the side of the bulb if it lights then you know you've got power if not then the problem is with the regulator or stator plate hope this helps and I'm not teaching you to suck eggs

[MK Monty]

Basically you are correct that it's generally colour to colour. Are you running an ignition switch with a key for kill and lights.. If not it's a bit easier. Start with the headlight it will have 2 feeds red and blue. If you follow the power through the bulb holder it will have another contact white? That needs to go to earth. Remove the brown from the loom and touch it to the bulb at the red and blue connection. Bike running. That will prove the bulb and the ground also your regulator is outputting. Once you know that works connect the brown from the loom and the brown from the bar light switch should get you power to the switch, you can then check for what's coming back. It's all a bit step by step I'm afraid but helps if you have a voltmeter. The horn should be easy. It should have a brown feed to one terminal and a white that goes up to the horn switch and is grounded when you push the button. Again when you know you have a light working proving you have voltage you can connect it to the horn direct and ground the other side to prove the horn works.. Also some looms don't have a purple only a brown. You will have to connect the brown and purple together or half the stuff won't work as it has no feed.. Greens are your ignition kill switch and can give you a hell of a rattle if you grab hold of it, it's not an earth.
PS
Always Good to put the town you live, on your profile, lots of clever people on here who are happy to help.. You may have one just down the road. Good luck

[Souly50]

Hi
Don't worry about suck eggs any help is appreciated and yes there is power and I have made sure all the earth all the way through have a clean surface and are attached in the correct way according to sticky book. The ignition switch is a key one nor cut out and that works when I turn it off.
Thank you both for the help I will try some of your suggestions and let you know how I get on.

[missing lynx]

try bypassing the ignition its not unknown for them to fail

[Souly50]

Hi Thanks for the help so far. OK i have some more questions if anybody can answer as i want to check the connections. On the main harness just where the horn is the harness branches off, there are three wires a grey and a pink which it stated on the site I brought it from these where to be used if I had a front break if not just tape up out of the way, so I have as I do not have a front brake but also there is two browns joined to one connection if that makes sense. Now I have assumed this is the feed to the horn as it fits perfect there. Here comes the question on the main handle bar switch just as the wires go across the top of the forks in the head set there is a branch off of a Brown and white which is sheaved and basically looks like due to the length they both go to the horn but then I have two brown connections and one white so which do I use to power the horn? I assume it would be the one coming from the main harness with the white from the handle bar switch but then if this correct what do I do with the brown that is with the white from the handle bar switch. I really hope that makes sense to everyone.

Stuart

[MK Monty]

Ok. Let's start with the brown and white that come from the light switch in the sleaving that is the horn and its return to the button and earth. The brown and its extra short brown needs to go to the lamp holder terminal block. Connect all Browns together but the junctions only tend to be in 3's so at a gues your little jumper goes in purple. I'm thinking your new loom doesn't have a purple but your headset bar switch does. Your brown is the main feed from the stator and regulator. Your original loom had 2 feeds brown and purple. It had three actually but we don't need to know at the moment. Because your new loom only has a brown anything supplied from the purple has no power. You will have purples connected at the headset but try plugging in the short brown.

[Souly50]

OK doing what you said with the browns and purple all lights are operating perfect so big thank you for that. The only thing not working is the Horn. It is brand new and I have used the white and brown from the switch. Is there a way of testing the horn off the bike? also does the horn have to be earthed the reason I ask is the plate that is attached to the horn which the two bolts go through to attach the horn to the bracket on the main fork struct have two rubber bushes I assumed these are to stop vibration on the horn.

[MK Monty]

Whey hey, getting there. The horn does not need to be earthed. The white going back to the switch is then earthed when you press the button. To test the horn remove the existing wires take a wire from the brown terminal in the headset and with a wire on the other horn terminal going to ground and the scooter running touch it to the horn direct. It should sound. Quack. Your horn could be a DC version so it could just click. Next step reconnect the white and with the temporary direct feed from brown see if the horn switch then works.

[Souly50]

Hi
I tried what you said and did get a Quack but once connected white to the horn and used the brown temporary wire to the other connection on the horn there was nothing and now if I go back to the test set up i.e. temporary brown and ground wire it does not Quack any more. So I remembered I still had the original horn which was rusted and the bracket on the horn was split so could not use hence me getting a new one. Anyway thought I would try that one so set up with the test you recommended and got a nice load Quack when I grounded the wire so put back the white and again nice Quack so put both wires from the switch and pressed the switch and the horn sounded. So have ordered another new horn and see how we get on. I can not thank you enough for all the help you have given me over the last few weeks to sort out the wiring I have no idea how long it would of taken me without yours and other help on this site. All that's left is to get it MOT, Taxed and registered and I am on the road. Anything I should be aware of with MOT and registration, I have the nova for the scooter and I believe I can ride it just to the MOT station and Back using the frame number as the reg until I get it Registered. obviously it will have no TAX till I have got the MOT and REG.

[Jono]

Souly50
Glad your now sorted, almost road legal .
Regards MOT as long as Scooter is Insured against Frame Number you can ride to MOT Station ( the Law says you should have previously booked MOT by Frame Number with Station).Try and find a MOT Station that is known for MOT of Classic m/c's thereby being sympathetic to poor brakes/lights & horn by today's standards.
Good luck Jono

[MK Monty]

Always great to have a result, bit of a bugger that the 50year old horn still works when the shiney new one is only good for the bin. It may well be a DC one try it on your car battery. It may be good if you decide to go DC at a later date. Get it down the MOT as soon as you can, it doesn't have to be finished 100% just safe for the road, you could be hanging around for the DVLA so will have the time to finish bits and bobs.
I always say join a local club, they all have blokes that can help you out, though after a rebuild yourself you will more skills than the ones who use a dealer to replace a cable.
Result well done.

[Paul Slack]

http://lambrettarestorations.blogspot.c ... -loom.html

[MK Monty]

That's what I said.. Folk keep buying the simple loom without the purple, if you have one connect it with the brown at your junction box at the rear with the output from the regulator. That's your feed. If you don't connect anything purple to the brown at the headset. I think is what the manufacturer of this loom tried to do with the short brown. It would have been nice if he had used a short purple but hey ho.