Baja Dune 150cc gokart help?

[Dang]

Just bought a use Baja dune 150cc gokart and trying to figure out how to get it start. It’s missing the key and the battery seem to be drain. I jump start it and open up the ignition switch. I connect wire 1 and 2 together while tapping on wire 3, nothing happen. I test it out with a voltage meter on the ignition wires to make sure it’s getting power but it’s not showing enough power. I make sure the jumper that’s connect is supplying power and there’s no short on the wire, the meter read over 12v. I also check the kill switch and unplug it to make sure it’s giving power. I try stepping on the brake to get it to start thinking that might engage and give it power but didn’t work. I don’t know what’s wrong with it but it’s not showing any power on the ignition switch or have any sparks when the wires are touch. Can some help me? It’s a Howhit 150cc engine, I research it and it’s basically a Cy6 engine.

 

[Hellion]

Aww, come on. Real go karts don't have keys or electric starters....

That thing is a dune buggy, dude. Who's the manufacturer?

I can't help you but maybe someone else can. In any case BUMP.

 

[Karttekk]

Aww, come on. Real go karts don't have keys or electric starters....

That thing is a dune buggy, dude. Who's the manufacturer?

I can't help you but maybe someone else can. In any case BUMP.

He mentioned it's a Baja 150 Dune.

---------- Post added at 09:26 AM ---------- Previous post was at 08:58 AM ----------

I think you mean a GY6 engine, not a CY6. Anyway, you should be able to jump the starter relay. Look for the fat red wire coming from the battery to a relay or a block with terminals on it. From there the wire should go to a starter post. The other battery wire is usually green or black. That should go to the other relay post I believe. Jumping over those terminals should get the engine cranking. You'll probably have to put a jumper wire over the ignition switch posts to power the ignition system too since there's no key. If it doesn't start, BYPASS the stop switches instead of disconnecting them. Unplug the leads from the stop switches then connect them together temporarily with electrical tape. If no luck still, remove the spark plug, put the coil/plug wire on it, lay it near metal to ground it then crank the engine & see if the plug gets spark. If you have spark, put the plug back in, shoot a quick blast of starting fluid in the intake and crank it again. If your compression is good, you have spark and fuel, it should fire. I'll include a diagnostic chart link from American Landmaster that might help you out. The GY6 engines are basically the same for the most part. Scroll to page 64, Electrical.

https://americanlandmaster.com/pdfs/LUTV/150cc-service-manual-14589R4.pdf

 

[Dang]

He mentioned it's a Baja 150 Dune.

---------- Post added at 09:26 AM ---------- Previous post was at 08:58 AM ----------

I think you mean a GY6 engine, not a CY6. Anyway, you should be able to jump the starter relay. Look for the fat red wire coming from the battery to a relay or a block with terminals on it. From there the wire should go to a starter post. The other battery wire is usually green or black. That should go to the other relay post I believe. Jumping over those terminals should get the engine cranking. You'll probably have to put a jumper wire over the ignition switch posts to power the ignition system too since there's no key. If it doesn't start, BYPASS the stop switches instead of disconnecting them. Unplug the leads from the stop switches then connect them together temporarily with electrical tape. If no luck still, remove the spark plug, put the coil/plug wire on it, lay it near metal to ground it then crank the engine & see if the plug gets spark. If you have spark, put the plug back in, shoot a quick blast of starting fluid in the intake and crank it again. If your compression is good, you have spark and fuel, it should fire. I'll include a diagnostic chart link from American Landmaster that might help you out. The GY6 engines are basically the same for the most part. Scroll to page 64, Electrical.

https://americanlandmaster.com/pdfs/LUTV/150cc-service-manual-14589R4.pdf

Yea I meant a GY6 engine. I took the cover up and use a screw driver to connect the 2 post where the fat red wire to power is connected to and the starter fire up. I took the spark plug out and test for sparks but there is none. Maybe it’s grounding somewhere that I need to bypass to get power into the spark plug?

 

[Karttekk]

Bypass any stop switches. There's usually one on the dash near the key cylinder and another one on the CDI box on top of the engine. Bypass the brake safety switch too if equipped. That plug looks fouled. Try a new one. You could also have a bad CDI module. Most modules are AC, Manco is one of the few karts that use DC modules. Follow the steps in the service guide I sent, that should help narrow it down. It's cranking anyway, that's a plus. If you have to start guessing what part could be bad, guess cheap. Maybe pick up a CDI module if everything else checks out. You'll get it, keep testing & report back.

---------- Post added at 01:41 PM ---------- Previous post was at 01:28 PM ----------

My Helix was trashed by the previous owner. To be sure, I picked up a new CDI module, a new coil/plug wire, spark plug and a magneto since he ran screws that were too long directly into the magneto and shorted it out. A definite candidate for the "Kart Mechanic Hall of Shame." Fired right up afterward and has run fine since.

---------- Post added at 02:22 PM ---------- Previous post was at 01:41 PM ----------

Something else I didn't think to mention is make sure the buggy is secure when you're doing the testing. If it has a parking brake, make sure it holds good. If not, either put the back wheels up on stands or have the kart against a wall or a tree. If it would happen to start and the throttle go wide open, it will launch unexpectedly. You don't want it going through your garage door or into the neighbor's pool. Actually the pool option may not be a bad idea if you don't care for your neighbor.

 

[Dang]

Bypass any stop switches. There's usually one on the dash near the key cylinder and another one on the CDI box on top of the engine. Bypass the brake safety switch too if equipped. That plug looks fouled. Try a new one. You could also have a bad CDI module. Most modules are AC, Manco is one of the few karts that use DC modules. Follow the steps in the service guide I sent, that should help narrow it down. It's cranking anyway, that's a plus. If you have to start guessing what part could be bad, guess cheap. Maybe pick up a CDI module if everything else checks out. You'll get it, keep testing & report back.

---------- Post added at 01:41 PM ---------- Previous post was at 01:28 PM ----------

My Helix was trashed by the previous owner. To be sure, I picked up a new CDI module, a new coil/plug wire, spark plug and a magneto since he ran screws that were too long directly into the magneto and shorted it out. A definite candidate for the "Kart Mechanic Hall of Shame." Fired right up afterward and has run fine since.

I connect the key switch wires 1 and 2 together and test it and got sparks on my spark plug. Put the spark plug back in and spray some starting fluid in the carb and it start right up the engine start running for a bit then die. When I took the spark plug out earlier I notice that it’s not wet so I assume it’s not getting any gas. I check my fuel line make sure it’s dripping gas down and it is. I notice my carb was dry when I took the air filter intake off to spray the starting fluid. So I assume the carb is plug and fuel is not coming in for it to start.

 

[Karttekk]

Check the fuel valve or petcock, it's up under the fuel tank. Most are vacuum operated. Vacuum pulls the diaphragm open to allow fuel to flow. Attach a vacuum pump to the valve, pull the valve open and lock the pump to hold vacuum and keep the valve open. Those carbs are stubborn. If mine sits for a good while it takes forever to start. If your fuel valve is mechanical or has an open/close lever make sure it's on OPEN. Sometimes it just takes time to get enough fuel in the carb to get it going. Spray the intake again, put a charger on the battery so it stays charged. A trickle of fuel in the line isn't enough, you'll need a good flow. I'm betting you'll be flying down your street any time now. You're almost there.

 

[Dang]

Check the fuel valve or petcock, it's up under the fuel tank. Most are vacuum operated. Vacuum pulls the diaphragm open to allow fuel to flow. Attach a vacuum pump to the valve, pull the valve open and lock the pump to hold vacuum and keep the valve open. Those carbs are stubborn. If mine sits for a good while it takes forever to start. If your fuel valve is mechanical or has an open/close lever make sure it's on OPEN. Sometimes it just takes time to get enough fuel in the carb to get it going. Spray the intake again, put a charger on the battery so it stays charged. A trickle of fuel in the line isn't enough, you'll need a good flow. I'm betting you'll be flying down your street any time now. You're almost there.

Thanks for all the tips. I took the carb apart to clean it and it was all gunk up. I am planing to just buy a new carburetor kit for it. I also notice that the clutch sprocket to the engine isn’t fully attach so when the engine is running it’s just spinning freely. The drive sprocket assembly is missing for the forward and reverse. Where can I obtain that part?

 

[Karttekk]

Try any of the standard places that are suggested here. GoPowerSports, BMI Karts, eBay, OMB Parts Warehouse, Azusa Parts. Google the kart model then parts. It may or not be available anymore though. Pretty sure Baja is out of business so you may end up fabricating something or getting it welded somewhere.

 

[Hellion]

Ahh, I meant the actual maker (or more broadly the country of origin), not the American subsidiary. Baja is just a catchier marque name than Yongkang Jinyi Vehicle Co. or whomever they are.

The buggy is Chinese.

 

[Karttekk]

Baja Motorsports has discontinued their go kart line.

http://www.bajamotorsports.com/

---------- Post added at 10:28 AM ---------- Previous post was at 09:53 AM ----------

See if you can contact Baja & ask if parts are available for yours. These parts might interchange.

http://www.bajamotorsports.com/syst...ja_Reaction_150cc_Go_Kart_VIN_PREFIX_L6K_.pdf

http://www.bajamotorsports.com/

---------- Post added at 10:31 AM ---------- Previous post was at 10:28 AM ----------

https://www.buggypartsnw.com/index....a-reaction-150-2-seater-reverse-assembly.html

 

[Dang]

I purchased a new carb and intake manifold now it stay running. I am having trouble trying to find part for the small sprocket gear that attach to the GY6 engine spindle. It’s missing like a center piece to keep the gear sprocket to catch so it won’t be loose and spin freely. I haven’t had any luck trying to find that piece. I post some pictures if anyone know where I can purchase one? Thanks

 

[950speed]

That’s the reverse assembly, you could buy a new one they are fairly common, but come at a price ~$150-200

 

[Denny]

You need a whole reverse gearbox assembly.

Denny

 

[950speed]

Yep! Unless your fine without reverse you could probably find a sprocket that was splined, although cheaper it might be more difficult

 

[Dang]

I don’t really need reverse. Is there another way I can just purchase a sprocket teeth and mount it straight to the spindle?

 

[Denny]

No you will need the reverse assembly.

Denny

 

[950speed]

No you will need the reverse assembly.

Denny

Is it not possible to just put a sprocket on there with the correct tooth count? I don’t see why not after all t would be only foreword which if he is fine for he can have.

Why is the whole assembly necessary?

 

[Denny]

The money spent on machining parts will be more than the reverser.

Denny

 

[950speed]

Ok so your previous statement wasn’t true. It’s possible to do as I said. But it may just be difficult to find one or machine one. Who knows a machine shop might charge less than $200 fo machine one.

Nevertheless it is still a viable option