First Electrical Problem HELP!

[TBR125]

I went to start my Agility 125 and I heard a "chink" sound from the starter area when I pressed the start switch. Of important note, I filled the fuel tank and the gauge read full. When I press the START switch the FUEL GAUGE is powered to empty in 1.5-2.0 seconds and the starter doesn't make a sound. Makes me think a short.

Where do I start? I am good with mechanics but don't know electrical harnesses yet. I can use a multi meter.

[TBR125]

Correction: The fuel gauge goes to empty if I apply either brake. It is not the start switch.

[CROSSBOLT]

You have a ground wire disconnected or corroded or loose somewhere. Typically for any Kymco scooter there is a ground point machine right near start relay/solenoid and reg/rectifier  plus up front behind/below headlight.

[TBR125]

Thanks for the heads up! I will start with that and get back when done.

[TBR125]

The fuel unit harness plug reads .6 Ohm and the rear brake light harness plug reads .8 Ohm. Is that standard or a short? The headlight and all turn signal harness plugs read 0 Ohms as well as the grounds.

[TBR125]

I have eliminated issues in the harness all the way to the main harness disconnect by the stem. The issue should be in this front harness.

[TBR125]

Problem found!

It's a brake light to fuel sender short. It is a ground wire issue like you said, thanks Crossbolt. The wires are marked on the diagram.

[CROSSBOLT]

Hey! Anyone who even is dimly aware of WHAT a Simpson 260 is must by default figger out what any problem is!

Oops! Mirror scale = 270! That makes you an expert!

How did they short together?

[TBR125]

Ha! It's the Simpson 270 series five. I found that treasure at a pawn shop for 15$ because it wouldn't take an internal battery. It was just a bent terminal.

Regarding the short, I wasn't able to pin point it for fixing as the resistance between the shorting wires increased as I unwrapped all the tape and then the short was gone. I will tape the offending wires separately so they hopefully can't touch again.

[CROSSBOLT]

Ha! It's the series five. I found that treasure at a pawn shop because it wouldn't take an internal battery. It was just a bent terminal. 15$

I had a 260 from 1961. Bought it to have a decent meter on a Navy ship! Had that until 2004 when we went full time RV park working.

[TBR125]

I should have a good meter for a long while then.

[TBR125]

*Updated*

After unwrapping the entire harness I found the culprit. The ground split in the photo is not wrapped separately from the yellow. They shorted after a wire strand poked through the insulation.

The clock was replaced 4 years ago under warranty and the dealer re-wrapped the outside but did not replace the connector protectors. I am now really determined to do any work myself. 5 minutes and a foot of tape would have saved my 3 days of searching and lack of transport.

[CROSSBOLT]

You have concluded like many of us here that you, me, we all can do a better job than nearly any dealer tech. Most techs are under a gun to do everything in a hurry and their pay is tailored to enforce this BUT that is really their problem! One little wire strand? That the one I think I see?

[TBR125]

It opened a 1 by .5mm hole in the insulation, slowly wore through with time apparently.

[TBR125]

Well, that exact short is gone but another remains. I know it is not between wires because I individually wrapped all harness wires with a total of 3 rolls of electrical tape. I am having trouble tracing the issue as it disappears whenever I move the harness.

Any suggestions before I build a new harness? I would like to eliminate the harness as the issue so I know it is an electrical component that I can test to locate.