electricity problems in kymco Agility 125

[CROSSBOLT]

200 ohms will not blow a 10 amp fuse as the current is only .06 amp. Less than 1/10 amp. That is not the problem.

I do not recommend the 15 amp fuse replacement for the 10.

Karl

[kymcoco]

I didn't think that the 200ohm is responsible for the fuse blow - in addition the 200ohm was behind the black fuse, not the red one which blows each time. On the red cable behind the fuse the electrometer was showing infinite resistence :| Anyway it resolved the not-stable input voltage of the starter.

Attached file - complete electric scheme of Kymco 125.  Red cable - after the 10A fuse - goes to regulator (checked, not grounded), then to ignotion switch and finally to the clock on the dashboard.
HERE A BIG QUESTION MARK - This scheme differs from the first one (the B&W scheme of the starting circuit) - here the fuses are 10A & 7A, whereas the 1st scheme contains fuses 15A & unknown.  And if you check cable colors on the 1st scheme, the 15A is on the red cable, ie where I have the 10A now.. Both schemes are from the same document - Kymco Agility 125 Service Manual.

[CROSSBOLT]

Welcome to the vagaries, inaccuracies and outright mistakes in Kymco service manuals! Use 'em for a general idea only! I suspect you have a wire grounded and methodical troubleshooting will find it.

Karl

[CROSSBOLT]

Kymcoco and onceinalife, I hope and pray neither of you were involved in the Paris tragedy.

Karl
 

[CROSSBOLT]

Kymcoco, what's the update? You still with us? I really want to hear you are OK and breathing.

Karl

[kymcoco]

Hello Karl!
Firstly I don't understand why I don't receive any more "Topic reply" when you add a new message to this thread :|

As for the Paris - thank you for your pray and your honest humanity, I don't live in Paris thus I was "only" watching the tragedy in media..   Onceinalife was lucky as well I hope.

As for the scooter - I was waiting until wednesday for the ordered fuses 15A (I ordered also spark plug) , today I had some time to test it.
Current status: It still doesn't start Even though I can hear the starter turning the engine - like there was not a spark. I checked the voltage going from the pulser coil, the values are low (0.0x V instead of 0.x V ) but as I searched on google it seems that it's only because I haven't got a special "peak volt-meter".. (?) I checked also the high voltage ignition coil before the spark plug - its resistence is correct. Now checking the manual, I should also check the voltage going from CDI to the high voltage coil. Battery is already almost below 12V, few last attempts with the start button remaining I think, then only mechanical crank..

Not too many things remain to check, I'm loosing my last hopes :/
 

[CROSSBOLT]

Yes! Glad to hear you are still above ground!

I am really confused about the electrical problem. First it was blowing fuses when you tried to start it now it is refusing to start. The problem description seems to change.

Karl

[kymcoco]

"First it was blowing fuses when you tried to start it now it is refusing to start" - since the beginning my big dream was to be able to start again my scooter!

Summary: The issue of blowing fuses seems to be resolved by the replacement of 10A by 15A (at least temporarily...).  After the fuel monitor disconnection (the 200ohms consumer) the ignition relais correctly receives 12V. So now it's time to hear the engine starting, but it's only turning over and seems not to receive a spark (?). And as I said in my last message - I bought a new spark plug and checked the coil's resistence and voltage, both are OK. I need to check whether the coil receives the right current (from CDI).

[kymcoco]

Trying to inspect the CDI, but it seems to be IMPOSSIBLE on Agility In the manual, the CDI inspection table is missing. According to eshops, the CDI on Kymco model Like is the same, thus I tried to find manual of Like on web - finally I have found one, but the CDI wire description contains errors and the table doesn't seem to be the right one. (unbelievable that a company can officially publish such 'document' ..)
Anyway, when I put the multimeter on connectors of the ignotion coil and I crank the motor (key is on), there's no input current. Looking at the wiring schema, it might be caused either by CDI or the key switch box (?)

[CROSSBOLT]

ALL Kymco manuals are loaded with errors. Machines change, manuals don't. Depends on what kind of meter you have: digital of any kind will not scan fast enough to pick up the firing impulse. Some analogs will show a "flicker" of needle movement which is enough to tell you there is an input signal.

Karl

[kymcoco]

My last test:  the spark plug put on the engine, each time I press the start button the plug fires a spark ...
Fuel tank is full.
WHAT ELSE TO CHECK PLEASE ?? 

[CROSSBOLT]

Have you checked valve clearances and timing?

Karl

[kymcoco]

I haven't done any test of valve, anyway the scooter was starting OK few months ago, there was just a "small problem" with electricity, it was not recharging the battery...
And now, after I've checked all the electricity, replaced some components, it doesn't start... Can it be sth like overfull because of many attempts to start it? Something like too much fuel sucked in the engine?
I tried today to check the tube from fuel tank to the engine over carburator, if it cannot be clogged, but it seems to be ok, at least the filder filter just below the tank.

[CROSSBOLT]

Any difference between spinning the engine with the starter 1. with spark plug in and 2. with spark plug removed?

Karl

[kymcoco]

Karl, by "spinning" you mean how the starter motor rotates the engine when I press the button? I don't realize it now, I was just watching the spark plug to see the sparks. Anyway, when the spark plug was out and I tried also mechanical crank, I don't understand why there was no resistence - I can press the crank very easily.