New wiring & No Start

[Little-Boo]

I need some help with the wiring on my 2006 Mastiff carbureted. For the longest time had been using the Wire-Plus system without issues and it finally pissed on me. I bought an Alex EHC from a certain person on this forum, and I think I got blindsided. I’ll find hope to find out if the EHC is gone, or the wires are crossed. The Harness is a new complete back bone and power along with the quick disconnect coil harness that runs from the coil to the ignition module.

The wires coming from the Coil to the Ignition Module start at the Coil itself and run Blue for the rear Cylinder, Red for power in the center and yellow for the Front Cylinder. So according to the 2006 universal schematic I have Blue, red, and Yellow which matches the schematic, however the JST connector on that harness going to the ignition module is Blue on the left, yellow in the middle and red on the right side. I bought the ignition module from HDM sometime in April or May, and the Complete harness from Derek and Donna some time ago, I figured Wire-Plus was not to be trusted therefore I got one just in case.

My question is should I change the JST connector on the ignition module and the Harness to match the Schematic, which is blue, red, and yellow. I feel like I am missing something but here I am tired of chasing wires. It cranks but will not start and there is no power to the ignition module. Any help will be greatly appreciated.


Carlos

 

[pauly]

https://thunder-heart.com/Tech%20Service%20PDFs/EI5012.pdf

this should help you Carlos.

Paul.

 

[pauly]

With the key on, handlebar switch set to run and all JST connectors but the one going to coil plugged in you should have the red Light on on the ignition module. If so, check which wire has 12 Volts on the loose JST connector on ignition module. (the one you left unplugged)
It should be the red one. If so, change the pins/wires around so the colors match. The bike should start.

 

[Rottweiler]

Hope that fixes you. I have a different ignition system now. So I can't compare.

 

[Jwooky]

The wires/colors should match from coil to ignition module. I would definitely re pin them to align.

 

[Mikeinjersey]

I believe you are concentrating your efforts on the wrong connector. Power to the coil comes from the ignition module and power to the ignition module comes from the EHC. You have to figure out why your red light is not coming on when you have the key on along with the run button. Look for 12 vdc across the red and black on connector 8 which would be the power from the EHC A19 to ground A23. Your starter is working so that means the EHC is getting the signal from the ign switch to come on so when the run button is selected the EHC should provide the 12vdc to the Ignition module.

 

[mastiffdave]

Boo, pm knotthead. He just did the exact thing on the mastiff that he rebuilt. He had all the wires out of that bike so many times he could tell you from memory..

 

[Jersey Big Mike]

I believe you are concentrating your efforts on the wrong connector. Power to the coil comes from the ignition module and power to the ignition module comes from the EHC. You have to figure out why your red light is not coming on when you have the key on along with the run button. Look for 12 vdc across the red and black on connector 8 which would be the power from the EHC A19 to ground A23. Your starter is working so that means the EHC is getting the signal from the ign switch to come on so when the run button is selected the EHC should provide the 12vdc to the Ignition module.

I believe he is dead on. It looks like the ignition module is mis-wired.
I'd pull off that wires at coil end and check for where the 12V shows up. I'm betting it will be on your yellow wire as I think the yellow and red are reversed.

 

[knothead]

The book is wrong and that was alot of issues with some of these service manuals...i have 4 ignition modules on the self and the are all wired just like what LittleBoo posted plus i have Jeffs bike disassembled in the shop now and its wired the same as Boo's picture....now with that said i have found some of the new harnesses that i install are wired wrong to so there again there is a problem and i have seen ignition module wired wrong as far as what color is in what slot in the connector...so honestly who knows whats right or whats wrong

If you match both jst connectors color to color you will be fine...and yes blue is rear cylinder, red is power and yellow is front cyclinder...just color match you wires in the jst connectors how it should be ,color for color, and hook it up to the corresponding spots on the coil and that is right... go from there and tell us what you get...

 

[Little-Boo]

Thanks to all of you for guiding me in the right direction. I am waiting for the tractor ignition switch and keys to come in. Then I am going to change the pins. I will first change the yellow and red wires to match both the coil and the ignition module. Like Mike says "they are reversed. The rest are fine because when I first attempted to see if the EHC was working I tried the Turn signals and four way flashers and they worked, next I did the high and slow beam and they worked, next I did the run button and the "N" signal and oil light came on. I next tried to start it and it turned fast and I figured it was going to start so I put the gas tank on, 3 fresh gallons of Premium gas and nothing just crank and crank. I have read more post and the service menual and still didnt start. But I hope to change that as soon as the tractor, switch comes in. Again thanks all of you Knothead, Jersey Mike, Mastiff Dave, Jwooky and Pauly; thanks for taking your time to help me out. I will keep you posted until it fires up.

Carlos

 

[Little-Boo]

I finally got the tractor ignition switch that I ordered and while I was at it I might as well get me a couple of spark plugs tester. The weather down here is not very cooperative some days its nice out and lately its been over 100 degrees, so the only time I was able to do anything was late in the evening or nothing.

Anyway, just wanted to let you that I switched the red and yellow wire coming out of the Ignition module the way it was discussed above got spark, the red light came on as it should on the ignition module and it is ready for the gas tank. Everything else works and I thank you for your advice, y Dog will be ready to ride tomorrow. I was going to finish it tonight but its !0:30 pm the heat is 87 degrees, sort of a cold front compaired to 105 today.

Thanks

 

[Th3InfamousI]

Glad you got it going! Caught this after you were done but I would have suggested before taking apart the JST just to test the theory you could have just switched the wires on the coil and or measured DC output on the RED/Yellow wire. 12v constant power would have been identifiable when RUN button was pressed.

 

[Little-Boo]

Glad you got it going! Caught this after you were done but I would have suggested before taking apart the JST just to test the theory you could have just switched the wires on the coil and or measured DC output on the RED/Yellow wire. 12v constant power would have been identifiable when RUN button was pressed.

Thanks for your comments but changing the wires did the trick for me. Now the wiring color matches the schematic and will some day help someone else working on the scoot with wiring issues. The Bike starts so quick that it surprised me when I hit the start button. I just barely touched the start button it fired up just like turning on a light bulb. I hope my light bulb doesn't fade out anytime soon. Thanks again for you help.

Carlos