wiring and starting By o0ohakko0o (Read 11,339 times)

[o0ohakko0o]

Ok JR i hope ive got it right but i have hooked up the black wire coming from break off the key switch and the green/yellow wire from the same switch to green/yellow in the harness.

hooked up the the other break switch coming from the harness the black wire to any black in harness that has 12v and the green/yellow to pigtail of the solinoid relay.
the pigtail coming from the solinoid relay that has female plug has a red/yellow wire and solid green wire that is connected to male plug
and at the front of thequad near ignition i have this


i hope i have hooked it up as said to ?

[o0ohakko0o]

Ive tried to add some photos to make sure this is correctly done ok
from the break switch as you can see below


the 2 wires which are Solid Black and Green/Yellow... The black wire is going off the key switch picture below


and the Green/Yellow wire is going into the harness as you can see below


The other break switch which is coming from the harness which has a solid Black and Green/Yellow wire....
The solid Black wire is going to


And the Green/Yellow wire is going to the solinoid relay picture below

[JR]

Ok so far all looks good except I'm going to ask about the plug in Reply #15? If I'm guessing right the blue/brown wires on the male plug go to the handle bar switch assembly that has the kill switch, light switch and start button? Is this correct?

You have it plugged into the female that has red/yellow and green/yellow. If this is so then we need to verify something. You are going to have to take the couple of screws out of the switch assembly and see if the blue and brown come from the start button itself. Open it and it need be take a good picture of the wires on this assembly. Here is the reason I ask this.

You have hooked up the brake light 12Vdc feed wires (black) correctly. You have hooked up the brake light/solenoid 12Vdc output wires (green/yellow) correctly.

Now when you hook up the battery wires along with the small wires attached to the battery cables (red & black) here is how one makes the engine turn over.

When you turn the key on you supply 12Vdc to the key switch via the small red fused wire and in turn the 12Vdc runs through the black wire off of they key switch.

It of course feeds to the black wires on the brake light switches you hooked up. When you press either brake handle the 12Vdc now feeds through the green/yellow wire to the starter solenoid and if you have them hooked up your brake light bulbs. Stay with me.

So now we have the positive side (red) 12Vdc flowing all the way to the starter solenoid but as in all circuits you have to have a negative (ground) side to complete the circuit. How do we do this? This is where the start button comes into play. The Chinese do not want you to start the engine without having a brake pressed thus that's why you send 12Vdc from the key switch through the brake light switches to the starter solenoid, it's a safety feature.

So we complete the circuit to the starter solenoid by sending ground from the start button to the solenoid relay via the red/yellow wire.

So if the blue/brown female plug is on the handlebar switch assembly we have to know what it goes too? The male plug with the red/yellow and green/yellow is going to be used but ONLY the red/yellow wire will be used. We will need to remove the green/yellow and terminate that wire.

Here's a simple diagram that shows you what we are doing with the starting circuit.





Once you open this and verify what is what we can complete the final circuit to be able to crank this engine.

JR

[o0ohakko0o]

Ok so that blue and brown wire is going to the switch and looks like its connecting to the electric start button





And i still have this plug here doing nothing but if you like we can wait for this BELOW

[JR]

Ok that's what I thought and it looks like the blue wire is soldiered to the plate on the switch and the brown wire goes to the center of the switch.

So now lets go back to the picture in Reply #15. You need to pull the green/yellow completely out of the male plug, remember the video that shows you how to remove a wire/pin from a plug? Use a very small screwdriver or the end of a paperclip and insert it in the little slot at the end of the plug. This will push the locking tang back and you can easily remove the wire. Terminate the green/yellow or cover it with tape, it is not needed.

Now at the same time remove the red/yellow, bend the tang back out and re-insert it into the plug to match up with the (brown) wire. In other words brown goes to red/yellow.

Now for the blue, we got to hook the blue up to GREEN and I mean the solid green wire in the harness that goes all the way back to the battery on the big BLACK wire = GROUND. So if you have a unused GREEN wire up close in a male plug pull it and insert it opposite the brown and we'll have it done.

Remember I said the start button is the NEGATIVE side of the starter solenoid.

So when you get that done you will do this:

Hook up battery Red to Positive, Black to Negative, make sure the fuse on small red wire is good. Make sure the black cable is hooked up to a clean spot on the frame AND it is also grounded to the engine AND the small solid GREEN wire is hooked up to the black battery cable as well.

Make sure the battery is charged.

Turn the key on
Press the brake handle
Hit the start button

If all connections are good and the starter solenoid along with the starter is good the engine should turn over.

Then we will need to see if you have the CDI and coil hooked up properly and see if we have a spark on the spark plug.

JR

[o0ohakko0o]

Nothing jr pressing the electric start button is doing nothing I've put a test light on the plug connecting to key switch when it is turned off ( key) the test light comes on but when ignition key is off the test light works but I don't know if this has got anything to do with it I'm struggling now ? Everything is brand new stator ,harness, starter fuse is good. i am confused lol but there seems to be power through black/white wires  if you got fb messenger or something be good but if not does not matter just i have to wait nearly 24hrs in responce as we are in different parts of the world lol.
Oh and i dont have any lights connected up at all as i dont want the lights the plugs are just dangling with them not connected to anything

[JR]

Ok on Reply #16 picture #2 is this the key switch wiring plug? If so then some of the wires are wrong. If you have power on the black/white wire then the key switch is backwards.

Now I need to know two things if this is indeed the key switch?

You need to unplug it and make sure you have 12Vdc on the red wire on the side going to the battery.

Second check the wire arrangements when it's plugged in. It appears the colors don't match? It's simple

Red to Red
Green to Green
Black to Black
Black/white to black/white.

JR

[o0ohakko0o]

ok my bad there is spark when the solid green is connected to blue or isnt i just checked it
key switch wires are solid black coming from break , solidd black going into the harness,solid red ,and black/white.
The second picture is coming from the key switch plug blow my thumb
there is power on black/white when key switch is off but when i turn the key switch on there is no power if it makes sense  im sorry for all this 

[JR]

I edited my last post go back and read

[o0ohakko0o]

Yes this is the Key Switch wiring plug and the color are correct
Red to Red
Green to Green
Black to Black
Black/white to black/white
when i just tested power 12Vdc on the red wire on the side going to the battery there was power
just another question the pigtail on the starter solenoid the two wires yellow/red and yellow/green i have the positive (red) thick wire on yellow/red and the electric starter wire on the yellow/green does this have a matter or no ?

[o0ohakko0o]

Sorry JR there is power on red wire battery side i just edited reply #24

[JR]

just another question the pigtail on the starter solenoid the two wires yellow/red and yellow/green i have the positive (red) thick wire on yellow/red and the electric starter wire on the yellow/green does this have a matter or no ?

NO NO NO You cannot have the red/yellow hooked up to the big red wire! That shorts out the system.

It's simple the red/yellow needs to be a single wire going from the pigtail of the solenoid to the wire we hooked it up to on the start button = brown.

[JR]

The solenoid has a BIG red wire from the battery hooked to one of the large terminals with a nut. The other terminal wire goes to the starter on the engine.

The small wire pigtail is generally red/yellow and green/yellow or green.

Hook up the red/yellow to the red/yellow and trace it out to make sure it is a single wire going to the brown wire on the start button.

Now the blue wire on the start button has to hook up to a ground wire, 99% of all harnesses have the small wire that is ground as GREEN. The ground wire generally branches out all over the harness to different things. DO NOT hook up green/yellow to the blue wire on the start button, if you do then you are hooking up 12vdc and causing a short.

Now as we said the other wire going to the solenoid pigtail needs to be hooked up to green/yellow.

[o0ohakko0o]

ok thats what i thought thats how it is ok now im using a multimeter when i put 1 probe onto the red wire on the key switch (battery side) and the other probe onto the positive of the battery there is no reading but when i put the probe onto the black (negative) sid of battery i get a reading of power

Ok what you say in reply #27 is all correct

[JR]

Again look at this diagram to make sure the solenoid relay is hooked up correctly: