Free printableComplete packsTSP-PK-04FLAGSHIP
The Electrical Fault-Finding Pack
Battery, charging, starter, fuses and wiring, in the order that finds the fault cheapest first. Four sheets and a meter.
Layout preview of page one. The PDF itself is typeset text, not an image.
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12 pages. No account, no sign-up, no newsletter. Print it, copy it, hand it to somebody else.
TSP-PK-04 · version v1.0 · September 2026. Opens in your browser's PDF viewer, where you can print directly.
The sheets inside this pack
Every one is also available on its own, free. The pack exists so you can print once rather than 4 times.
The problem it solves
Electrical faults on these machines get diagnosed by replacement, in descending order of cost: battery, then regulator, then stator, then CDI. It is an expensive way to find a corroded earth strap, and the corroded earth strap is very often what it was.
There is no wiring diagram for your machine. That is not a research failure — experienced owners describe factory loom colours as varying between machines of the same brand and model, and every widely circulated colour chart we examined disagrees with at least one other. A diagram from somebody else's scooter is worse than none, because it will be believed.
What works instead is a meter and a method. Three voltage readings narrow almost any electrical fault on these machines: rested, charging, and current draw with everything off. After that it is continuity, connectors and earths — and earths are where a surprising share of these faults actually live.
The sheets are ordered by cost. Everything free comes before everything that has to be bought, and nothing in this pack ever tells you to find the yellow wire.
The mistakes this sheet exists to prevent
- Replacing the CDI first. It is the most expensive part in the circuit and among the least likely to have failed.
- Trusting a wiring colour chart found online. There is no universal standard and the charts contradict each other.
- Cleaning the battery terminals but not the engine-to-frame earth strap.
- Fitting a larger fuse to stop one blowing, which moves the failure into the wiring.
- Measuring the battery straight after a ride, which reads high and proves nothing.
Who it is for
- Anyone chasing an electrical fault with a multimeter
- Owners on their second or third battery in a year
- Anyone who has been told the stator or CDI is at fault and wants to check before buying
What is on it
- Battery and charging tests, with the only two voltage thresholds we could source
- The starter chart, which begins with a mechanical check rather than an electrical one
- Fuse mapping for a machine with no legend, plus verified blade fuse colours
- Wire tracing and connector mapping with somewhere to record what you find
How to use it
- 01Start with the battery sheet. A weak battery makes every other reading unreliable.
- 02Do the free checks — earths, connectors, fuses — before buying any component.
- 03Record every reading, including the ones that came back normal.
- 04Never work from a colour chart. Every branch in this pack ends at something you measured.
Use it with the registry
Other sheets you may want
- Battery and charging system test sheetThree voltage readings diagnose most electrical faults on these machines. Two thresholds are sourced; the rest is direction of change.
- Scooter starter clicks but will not turn overOne mechanical check first, then three electrical ones. The click itself tells you more than most people realise.
- GY6 wiring colour and continuity notes sheetThere is no universal wiring colour standard on these machines. This sheet records the one your machine actually uses.
Free to print, copy, and share — including in forums, clubs and workshops. If you find a mistake on this sheet, tell us and it gets corrected. Quote TSP-PK-04 and the version so we know exactly which sheet you mean. All printables.