How to connect a switch on a scooter? general recommendations

The main differences between switches

Products from Chinese manufacturers, as a rule, use one of two types of switches - DC or AC. The physical feature of the former is that it is much larger in size. The principle of energy accumulation for spark transmission also has a different nature. In DC, a rechargeable battery is used to store the spark (the switch is powered directly from a 12 Volt battery). In the case of AC type switches, this energy is supplied through the use of one generator coil (the switch is powered by a ~ 160 Volt coil). This is where the differences between the presented varieties end.

Signs of a faulty switch: how to check the switch yourself.

Purpose and design features of the switch.

A switch is one of the elements of a car's electrical equipment. His task

– ensuring normal operation of the contactless ignition system. The assembly is fastened in the engine compartment.

The device is reliable, able to withstand severe vibrations and shock loads

This is very important, because the switch housing contains sensitive electronics

At the heart of the VAZ switch

– standard L 497 microcircuit, which controls an “NPN” type transistor.

>Scheme feature

– possibility of programming by the user and setting the required delay coefficient. Starting a cold engine directly depends on the correctness of this indicator.

Thanks to precise settings

, you can speed up the crankshaft rotation speed (while eliminating failures in operation) and guarantee high-quality traction of the power unit.

The main parameters of the switch device include:

Voltage range – from 6 to 16 Volts; operating voltage level – 13.5 Volts; ensuring an uninterrupted spark when the crankshaft rotates in the range from 20 to 7000 rpm; switching current – from 7.5 to 8.5 A.

Signs of a faulty switch.

One of the main symptoms of a faulty switch is loss of spark.

. The engine starts hard and stalls from time to time, causing interruptions in operation.

But don’t rush into replacing it - it’s important to make sure of the reason, because loss of spark can occur for a number of reasons - failure of the Hall sensor, broken timing belt, faulty ignition coil, poor contact in the distributor cap, wiring problems, and so on

Therefore, first of all, a comprehensive diagnosis is necessary. The fastest and most effective way in this case can be a car diagnostic scanner. Most of this type of device is quite easy to use and has an affordable price.

Of those presented on our market, we can recommend paying attention to the multi-brand scanner Scan Tool Pro Black Edition

The advantages of this model include diagnostics of not only the engine, but also other components. Compatible with 99% of new and old cars since 1993, quite easy to use and has wide functionality.

If diagnostics of other nodes does not produce results

, then we can move on to our “hero”. But how to check the switch, since the device has a very complex design?

How to check the switch yourself.

Most car enthusiasts don’t bother with diagnostics and simply install a new unit. This method has its advantages.

Firstly

, there is no need to waste time checking - just install a new part.

Secondly

, you can immediately determine whether this is the reason or not. In fact, there is no need to be afraid of the work, because checking the switch takes a few minutes.

So, to carry out work at home, a test lamp (nominal voltage should be 12 Volts) and a standard set of keys are enough.

With their help, you can verify the presence or absence of pulses, and later make a decision about the serviceability of the device itself.

Algorithm for checking the switch:

To begin work, it is advisable to disconnect the battery so as not to accidentally short-circuit the wiring that you will unscrew.

Using an eight-point wrench, unscrew the nut and remove the wiring from the ignition coil marked “K”. This wire is easy to recognize - it is brownish in color and goes to the terminal labeled one on the switch;

Connect this wire through a control light to terminal “K” on the ignition coil, and then connect the battery;

Turn on the engine starter and observe the lamp's actions. If it blinks, then the switch is working. If the light bulb does not show any signs of life, then the only way out is to replace the device.

If there are doubts about the serviceability of a part, the check should be carried out on a special stand (there is always one at the service station).

In this case, it is possible not only to determine whether the product is working, but also to measure the duration of the pulses.

When the first suspicions appear, you should not immediately change the switch or spend money on a specialist. You are quite capable of doing the job yourself.

Moreover, now you know how to check the switch on the VAZ 2109 and other models of the domestic brand. All that remains is to allocate time and prepare a minimum set of tools. Have a good trip and of course no breakdowns.

Checking the regulator-rectifier and voltage generator

Disconnect the battery. Switch the device to 10 A.

We put the red probe on the c/h wire, and the second probe on the minus wire - the green wire. Turn on the ignition. We pull the kickstarter leg. The device can show 5 - 10 A. This means that the voltage generator, regulator-rectifier, electrical wiring and fuses in the circuit from the generator to the battery are working.

If all this works, but there is no spark, then all that remains is to check the switch. It cannot be disassembled and has a complex electronic circuit inside. Therefore, it can only be tested on another similar working scooter. Finding a Japanese switch can be difficult. But there are many Chinese analogues, they work no worse than the original ones.

This troubleshooting sequence - no spark on dio 34, can be used on any 2t or 4t scooter or moped. All you need is an electrical circuit for the scooter, a universal set of screwdrivers and wrenches, and a multimeter (tseshka).

That's all.

Those who are interested will be able to find the problem with the spark on their scooter or moped and fix it with their own hands.

Do not be afraid. Try it.

If you have any questions, write. We'll figure out.

Bye everyone!

Repair VAZ 2108 2109 21099

Friday, July 10th, 2015

Every owner of the VAZ 2109 should know the ignition circuit. Without knowing this circuit, you will not be able to start the car in case of ignition problems. Moreover, this scheme is elementary simple. The VAZ 2109 is equipped with a contactless ignition system. It consists of the following components: switch, ignition coil, distributor, Hall sensor, high-voltage wires and spark plugs. The task of the ignition system is to provide a timely, cyclic spark to the engine cylinders. Let's take a closer look at how the clamping circuit works.

Ignition circuit for VAZ 2109

ignition of the VAZ 2109: power is supplied to the ignition system through a relay. Until the key is in the ignition position, the relay will not turn on and supply power to the circuit. As soon as the key is turned, the ignition system is energized. +12V power from the battery is supplied to contact B of the ignition coil, the 4th contact of the switch. The Hall sensor powers the switch itself

Please note that the ignition relay is powered through the mounting block, and if there is poor contact in connectors Ш1, Ш8 or for some reason the track oxidizes or burns out, the ignition system will not be powered and the VAZ 2109 will not start. In order for a spark to begin to form, you must crank the engine crankshaft.

Together with it, the camshaft will turn and the Hall sensor will send an impulse to the switch. The commutator, in turn, will connect contact K of the ignition coil to ground, resulting in a spark appearing on the central wire. When the distributor slider connects the central wire and the wire leading to a specific engine cylinder, a spark will jump on the spark plug, igniting the combustible mixture. The engine will start. When it is necessary to turn off the engine, the driver, by turning the key in the ignition switch, turns off the relay, which in turn disassembles the power supply to the system. The switch and ignition coil become de-energized and stop working. The most common malfunctions of the VAZ 2109 ignition system: 1) Failure of the switch. 2) Failure of the Hall sensor. 3) Poor contact of the slider in the distributor. 4) Lack of power supply to the ignition system of the VAZ 2109. Go to Home.

Checking the ignition coil

Disconnect the battery and remove the beak on the scooter. We disconnect the connector on the switch and measure the resistance on the coil with a meter. We put one probe in the connector on the black wire, and the second on the negative (green wire). There should be 4 ohms - this means that the wiring and the primary winding of the coil are working properly.

Next step.

We check the second winding of the coil. We take out the probe from the contact of the green wire and insert it into the candlestick instead of the candle. And we leave the other probe on the contact of the h/w wire. The resistance should be about 7.85 kOhm. This indicates that the second winding, the armored wire and the candlestick itself are in good working order.

And if the device shows a break (i.e. does not react at all), then remove and check the candlestick and armored wire separately. If they ring, it means a break has occurred in the ignition coil. It cannot be repaired, it is solid, you will have to replace it with a new one. It's inexpensive and you can always buy it without any problems.

AC switch

It differs from DC switches in the ability to do without a stable 12V current. It is designed a little differently, because, despite having a more conventional design, it has a more complex connection to the electrical circuit. Unlike DC switches, AC switches are mostly without a speed limiter due to their small size and fairly simple design; they can boast of the ability to operate perfectly in the absence of a number of nodes, without which a DC switch cannot work in principle. Even if you remove the battery, relay-regulator, ignition switch, keep only the high-voltage generator coil and the Hall sensor, and the scooter will still start and drive. There are quite cleverly organized switches of the provided type that can compete with the DC type, but this is rare. Despite the lack of need for direct current, speakers are very dependent on alternating current and the relationship between the engine block and the frame, and if you burnt or damaged one coil in the generator, which produces high voltage, then the scooter will not start under any circumstances.

Pinout

If you have a 4T motor installed on your scooter, the pinout of the switch will depend on what type the scooter requires. For DC it will be as follows:

The leftmost terminal on top should connect to the generator sensor.
Ground is connected to the terminal located under it. You can tie the negative wire, for example, to the body of a moped; it is important that the part is metal.
The upper terminal, located in the center, is connected to the wire leading to the ignition coil drive.
The one located under it is also connected to the negative wire (ground).
The wire from the ignition switch is connected to the upper rightmost terminal, which is needed to turn off the engine.
The power wire is connected to the terminal located under it; it also comes from the ignition switch.

If you have an AC type, the location of the terminals is the same, but they are connected differently:

We move from left to right, first the top row, then the bottom.
Here the wire from the generator sensor goes, as in the previous version.
Next comes the ignition coil wire.
And at the end there is a “silencer” for the ignition switch.

The first two terminals are the negative wire, “ground”.
To the last remaining terminal we connect the power wire from the high-voltage winding of the generator. This point is the main difference when connecting an AC switch from a DC one.

Scooter Honda Dio AF 18 27

The Honda Dio AF 18 has a slightly different switch, made in Japan, which is why the pinout of the scooter is a little unique, and the mounts on the switch are different. It is connected as follows: from left to right, first the upper, then the lower terminals. Location:

Hall Sensor.
Ignition coil.
Weight.
Ignition lock.
Power wire from a high voltage coil.

Yamaha Jog Scooter

Several types of generator can be installed on this type of motor vehicle. The most common option has 5 contacts, with wires already coming out of it. Therefore, if you have original wiring, you need to connect as follows:

Orange should lead to the ignition coil and alternator.
Black - to the ignition switch.
Purple – Hall sensor.
The remaining two wires are connected to the ignition coil.

Chinese scooters

Typically, such vehicles have standard switches, which were described above. The connection diagram depends on whether the AC or DC device is installed on your vehicle. It is worth remembering that different types of switches are not interchangeable.

How to connect a switch on a scooter? General recommendations

A huge number of 4t scooters are offered in Russia. Low-quality switches are installed in budget-class models, which tend to burn out under the influence of increased load or moisture. This issue may also affect owners of more expensive equipment, because with the help of switches, manufacturers limit the maximum speed of movement. Before performing any work, you should carefully familiarize yourself with the electronic features of your vehicle. This will save a lot of money on contacting specialized professionals and will make the procedure as fast and comfortable as possible.

Ignition circuit elements.

One of the most important electrical circuits in a scooter is the ignition circuit. It includes a CDI ignition module (1), an ignition coil (2), a spark plug (3).

CDI ignition module.

The CDI ignition module (1) is made in the form of a small box filled with compound. This makes it difficult to disassemble the CDI unit if it malfunctions. Although the modular design of this unit simplifies the process of replacing it.

There are 5 wires connected to the CDI module. The CDI module itself is located in the bottom of the scooter body near the battery compartment and is secured to the frame with a rubber clamp. Access to the CDI block is made difficult by the fact that it is located in the bottom part and is covered with decorative plastic, which has to be completely removed.

Ignition coil.

Ignition coil (2). The ignition coil itself is located on the right side of the scooter and is mounted on the frame. It is a kind of plastic barrel with two connectors for connection and a high-voltage wire output that goes to the spark plug.

Structurally, the ignition coil is located next to the start relay. To protect against dust, dirt and accidental short circuits, the coil is covered with a rubber cover.

Spark plug.

The ignition coil is connected to the A7TC spark plug (3) using a high-voltage wire.

The spark plug turned out to be cleverly hidden on the scooter, and it can take quite a long time to find it the first time. But if we “walk” along the high-voltage wire from the ignition coil, the wire will lead us straight to the spark plug cap.

The cap is removed from the candle with a little effort. It is fixed to the spark plug contact with an elastic metal latch.

It is worth noting that the high-voltage wire is connected to the cap without soldering. The insulated stranded wire is simply screwed onto the screw contact built into the cap. Therefore, you should not pull the wire too hard, otherwise you can pull the wire out of the cap. This can be easily fixed, but the wire will have to be shortened by 0.5 - 1 cm.

It's not so easy to get to the spark plug itself. To dismantle it, a socket wrench is required. With its help, the candle is simply unscrewed from its seat.

Starter (8). The starter is used to start the engine. It is located in the middle part of the scooter next to the engine. It's not easy to get to.

Electrics and electrical equipment of a scooter

Dedicated to all owners of Chinese scooters...

To begin with, I would like to present a wiring diagram for a Chinese scooter.

Since all Chinese scooters are very similar, like Siamese twins, their electrical circuits are practically no different.

The diagram was found on the Internet and is, in my opinion, one of the most successful, since it shows the color of the connecting conductors. This greatly simplifies the diagram and makes it more comfortable to read.

(Click on the image to enlarge. The image will open in a new window).

It is worth noting that in the electrical circuit of a scooter, just like in any electronic circuit, there is a common wire . On a scooter, the common wire is the minus ( - ). In the diagram, the common wire is shown in green . If you look more closely, you will notice that it is connected to all the electrical equipment of the scooter: headlight ( 16 ), turn relay ( 24 ), instrument panel backlight lamp ( 15 ), indicator lamps ( 20 , 36 , 22 , 17 ), tachometer ( 18 ), fuel level sensor ( 14 ), horn ( 31 ), tail light/brake light ( 13 ), start relay ( 10 ) and other devices.

First, let's go over the main elements of the Chinese scooter circuit.

Egnition lock.

Ignition switch ( 12 ) or “Main switch”. The ignition switch is nothing more than a regular multi-position switch. Even though the ignition switch has 3 positions, the electrical circuit uses only 2.

When the key is in the first position, the red and black wires are connected. In this case, the voltage from the battery enters the electric circuit of the scooter, the scooter is ready to start. The fuel level indicator, tachometer, sound signal, turn relay, and ignition circuit are also ready for operation. They are supplied with power from the battery.

If the ignition switch malfunctions, it can be safely replaced with some kind of switch like a toggle switch. The toggle switch must be powerful enough, because the entire electrical circuit of the scooter is, in fact, switched through the ignition switch. Of course, you can do without a toggle switch if you limit yourself to short-circuiting the red and black wires, as the heroes of Hollywood action films once did

1 is shorted to the housing (common wire). In this case, engine operation is blocked . Some scooter models have an engine stop button ( 27 ) to block the engine, which, like the ignition switch, connects the white- black and green (common, body) wires.

Generator.

The generator ( 4 ) produces alternating electric current to power all current consumers and charge the battery ( 6 ).

There are 5 wires coming from the generator. One of them is connected to a common wire (frame). The alternating voltage is removed from the white wire and supplied to the relay regulator for subsequent straightening and stabilization. The yellow wire removes voltage, which is used to power the low/high beam lamp, which is installed in the front fairing of the scooter.

Also in the design of the generator there is a so-called hall sensor . It is not electrically connected to the generator and there are 2 wires coming from it: white- green and red - black . The hall sensor is connected to the CDI ignition module ( 1 ).

Relay regulator.

Regulator relay ( 5 ). People may call it a “stabilizer”, “transistor”, “regulator”, “voltage regulator” or simply “relay”. All these definitions refer to one piece of hardware. This is what the relay regulator looks like.

The relay regulator on Chinese scooters is installed in the front part under a plastic fairing. The relay-regulator itself is attached to the metal base of the scooter in order to reduce the heating of the relay radiator during operation. This is what the relay regulator looks like on a scooter.

In the operation of a scooter, the relay regulator plays a very important role. The task of the relay regulator is to convert the alternating voltage from the generator into direct voltage and limit it to 13.5 - 14.8 volts. This is the voltage required to charge the battery.

The diagram and photo show that there are 4 wires coming from the relay-regulator. Green is the common wire. We have already talked about it. Red is the output of positive DC voltage 13.5 -14.8 volts.

The regulator receives alternating voltage from the generator through the white wire to the relay. Also connected to the regulator is yellow wire coming from the generator. It supplies the regulator with alternating voltage from the generator. Due to the electronic circuit of the regulator, the voltage on this wire is converted into a pulsating one, and is supplied to powerful current consumers - the low and high beam lamps, as well as the dashboard backlight lamps (there may be several of them).

The supply voltage of the lamps is not stabilized, but is limited by the relay regulator at a certain level (about 12V), since at high speeds the alternating voltage supplied from the generator exceeds the permissible limit. I think those who have had their dimensions burned out due to malfunctions of the relay-regulator know this.

Despite all its importance, the device of the relay regulator is quite primitive. If you pick apart the compound with which the printed circuit board is filled, you will find that the main relay is an electronic circuit consisting of a thyristor BT151-650R , a diode bridge on 1N4007 , a powerful diode 1N5408 , as well as several wiring elements: electrolytic capacitors, low-power SMD transistors, resistors and a zener diode.

Sports Switch

Even such a modernized moped as Alfa Sport needs professional and high-quality tuning. This is necessary to increase speed and dynamics, as well as to improve the performance of the Chinese model.

Not only the cylinder-piston group, but also the commutator has a significant impact on the dynamics and speed.

Tuning

The moped will be able to accelerate to 13 kilometers per hour if you use a 15-17 tooth sprocket

It is important to remember that not only the rear and front sprockets must be replaced, but also the chain

To increase the speed of the moped, you can install a 15-tooth sprocket and replace the chain

The optimal solution would be to equip the equipment with additional:

glove compartment for necessary tools;
stand for a glass of water.

Considering that this model does not have a very comfortable seat, it can be replaced with a more rigid one, made of high-quality plywood (15 mm).

Repair

Like any other equipment, this moped also requires repairs periodically. To make a sports model as good as new, you need to:

adjust valve clearances;
remove and reinstall cylinder heads;
if the valves lose their seal, the cylindrical heads should be disassembled;
Reinstall the chain, piston and piston wheels.

Scooter electronic ignition device

The modern ignition system of a 4t scooter is designed as follows: the switch and coil, which are its main elements, supply high voltage to the spark plug, which generates an electrical discharge that can ignite the fuel. The coil generates high voltage due to electromagnetic induction. The switch is needed to distribute its interruption voltage at the right time. Inside there is an electronic circuit, a thyristor and three outputs for wires. At the right moment, the switch supplies voltage or turns it off.

The principle of operation of the scooter ignition system is as follows: the battery supplies voltage to the coil, which is often connected to a switch in one unit, the switch supplies voltage to the spark plug, and decides when to interrupt it. The mixture in the cylinders lights up at the right time. The correct operation of the engine and whether it will start at all depends on how the ignition is configured and set.

Switch

In many scooter models, the commutator is combined with a coil, so if one of the devices fails, the entire unit has to be replaced. Such spare parts are inexpensive.

Externally, the switch looks like a plastic box. Inside there is a microcircuit, a variety of electronics that cannot be repaired. In addition, there is a thyristor. The task of this element is to interrupt the electrical impulse at the right moment; for this purpose it has three outputs. When current enters one of them, the thyristor turns into a conductor, and the current moves from the input contact to the output. When a certain voltage is reached and the current drops, the pulse is interrupted, after which the Hall sensor returns the thyristor to its original position so that the signal arrives again at the third output. The process is repeated every time the voltage is applied again.

Ignition coil

A high-voltage coil is used to convert a voltage of 12 volts into several thousand, which will be enough to ignite a mixture of gasoline and air. The device operates on a principle based on electromagnetic induction.

For this, two types of winding are used - primary and secondary. They differ in thickness and both are wound on a metal base. Due to this, a magnetic field is formed between the secondary and primary windings of the ignition coil, which is capable of pumping an electric charge. The primary winding has much fewer turns. Passing through it, an electric current creates a voltage induced along the secondary winding. As a result of this impulse, the initially small voltage produced by the battery increases to several thousand volts.

After this, an electrical impulse is supplied to the spark plugs using a switch. It is important that this occurs at a precisely specified moment of movement of the piston in the cylinder. The current to the spark plug is transmitted through a thick high-voltage wire, which virtually eliminates the loss of current during movement.

Spark plug

The spark plug is responsible for igniting the combustible mixture in both the 2T and 4T scooter ignition systems. The following types are distinguished:

To make the right choice, you need to decide on the operating mode of the motor. Cold plugs have a short insulator, they can easily remove heat from the electrodes, as a result of which they hardly heat up. Hot candles operate on a different principle. Their insulator is long, it prevents the rapid removal of heat, as a result of which the electrodes heat up. There is no fundamental difference, but it is easier to start when cold if you use hot spark plugs, and a warm engine runs better when cold. It may make sense to change them depending on the time of year or storage conditions of the equipment.

If the spark plug does not warm up enough, carbon deposits will appear on it, which prevents it from working properly. This may cause the engine to stop starting. The problem can be solved in several ways: adjust the carburetor by leaning the mixture, or select more suitable spark plug models. If the spark plug overheats, the mixture will ignite too early and the engine will lose power and fuel consumption will greatly increase. To prevent this from happening, you need to set the ignition correctly. In this option, sparks on the spark plug will appear earlier, and the engine will start easier.

In a scooter, the generator is located in the engine, so it is not visible to the naked eye. The task of this element is to generate current when the equipment is moving and recharging the battery. If it doesn't work, you won't be able to continue driving because the battery will lose its charge very quickly.

The device generates alternating current and powers the entire electrical system of the scooter. There are five wires going to the generator, one of which is ground and is connected to the frame. The other, usually white, goes to the relay regulator. This relay acts as a rectifier and stabilizes the voltage.

The low and high beams are connected to the yellow wire. A hall sensor is connected to the generator. There are two wires coming from it - red-black and green-white. The sensor is also connected to the CDI ignition module.

Buying a switch

Purchasing a switch is the easiest and fastest way out, since you do not waste time, effort, and the cost of this mechanism is not so high as to save much on it. This is really the most reasonable solution that you can come up with in a situation where your switch has burned out

However, again, it is very important that you check everything correctly, do not use only a tester, but carry out a full procedure for checking the switch so that you can say with certainty that this is the reason. Otherwise, you will just spend money on a new part, but your scooter will still not function

Checking the power supply of a DC CDI switch

If you have the wire of the high-voltage coil of the generator hanging idle (provided that everything was like this from the factory, and not after the intervention of some “guru”) - switch the tester to the DC measurement mode in the 20 V range. Look for the wire on the switch nutrition. Usually this is a black or gray wire; we touch the ground with one probe and the power wire with the other:

If the display shows zeros, look for an open circuit in the power wiring.
If the voltage is significantly less than 12v, look for oxidation or check if your battery is charged
If the voltage is 12v or a little more, then everything is in order with the power supply and you can check further

The power supply to this switch is in perfect order.

Stock switch for scooter

A stock or original switch is the one that is installed on the vehicle from the factory. Its main advantage over others is that it is already designed for the equipment with which it operates; it is often equipped with a limiter so that the engine does not develop speeds that are dangerous to the life and life of the main bearings, the entire crank mechanism, cylinder-piston groups and other structures and assemblies. The stock commutator is the main source of a well thought out engine's longevity, efficiency and durability. Those who take the risk of replacing a factory switch with a sports (tuning) one are risking a lot. Those who do not fully understand what they intend to do risk even more. Inept installation of such parts and their subsequent use with a conventional engine often lead to a decrease in service life and the death of the engine, sometimes on the same day.

Signs of a broken switch

During the operation of the car, unpleasant symptoms may occur, indicating a malfunction of the ignition system.

A possible reason for this may be incorrect operation of the switch. Here are the most common symptoms that should suggest a possible breakdown of this device:

Can't start the engine. There is no spark when the starter is running.
The engine starts and runs normally at low and medium speeds, but cannot be revved up at high speeds. The engine is not running at full power.
The car stalls when moving away, although it idles stable.
The engine starts, but does not run for a long time and immediately stalls.
The engine begins to operate unstably - “triple”, reaching a certain speed level. When cold it can start quite normally.
The engine may periodically, without any pattern, stall, then work normally again. The battery discharge indicator lights up. The tachometer needle shows sharp changes in the number of revolutions.

Scooter ignition system design

The scooter's ignition system is needed to ignite the gasoline entering the cylinders. It is very important that the moment of fire is chosen accurately, otherwise the scooter will not move. Ignition is provided by a powerful electrical discharge issued by the spark plug. This requires a voltage of at least 15,000 volts, which can only be obtained thanks to the ignition coil, which converts the voltage supplied by the battery. Older models were equipped with contact cam ignition; modern ones are equipped with contactless ignition, which proves to be better and more practical.