2009 6150 two seater go cart GY6 150cc

[Tomas458Socom]

Is there somewhere that I can get an accurate Wiring diagram? I am finding many diagrams but being it's Chinese. I am also seeing that many of the diagrams do not actually reflect the actual wiring of what is out there. Along with a mid change of AC to DC CDIs. We have had this for a few years so now we are trying to get it up and going with grandkids wanting to ride around in it. Swapped the jug and head piston and rings new stator,CDI, voltage regulator. No spark so I need a wiring diagram as you know how it goes when you buy someone else's project you don't really know what you got. Tried firing it up yesterday and no spark.

 

[Functional Artist]

To be honest, there are so many variations of them Chinese buggies out there, that finding an accurate wiring diagram, for your specific kart is probably going to be very difficult, if not impossible.

Plus, the wire & connectors on them are so cheap that, after banging their heads
...& then, pulling most of their hair out most folks just make their own wiring harness.

There are a few guys on here that should be able to help you figure it out.

 

[electraglide]

Are you trying to start it via electric start or pulling the cord ? ... try pulling the cord ... if no spark .. you may have other issues besides the electric starter/wiring. Pulling cord no spark needs to be fixed first. Next .... try bypassing the starter switch.( jump start ) connect 12v neg to engine housing and pos to starter motor. ( no more than 4 seconds worth of juice ) if it starts or wants to start we can figure the rest out afterwards.

 

[electraglide]

Post pics of the engine and dashboard/panel ... several angles

 

[Tomas458Socom]

Are you trying to start it via electric start or pulling the cord ? ... try pulling the cord ... if no spark .. you may have other issues besides the electric starter/wiring. Pulling cord no spark needs to be fixed first. Next .... try bypassing the starter switch.( jump start ) connect 12v neg to engine housing and pos to starter motor. ( no more than 4 seconds worth of juice ) if it starts or wants to start we can figure the rest out afterwards.

Electric start

Post pics of the engine and dashboard/panel ... several angles

 

[Tomas458Socom]

It turns over but no spark gonna go through and test and ohm out what I can until then. And find out if it's An AC od DC CDI

 

[BrownStainRacing]

It turns over but no spark gonna go through and test and ohm out what I can until then. And find out if it's An AC od DC CDI

Here's diagram for AC cdi. blk/red wire from stator wire will power the cdi. If it's not there, then it's a DC cdi.

A DC cdi will get its power from the battery.

Disconnect the kill wire, incase there's a bad safety switch inline some where.

Then run a wire straight from the battery to cdi power, check for spark.

Google Search

 

[Snaker]

Your photo shows it as a ASW 6150.
I'm guessing that your reference to Hammerhead would be for the powerplant? There is a brand of machine Hammerhead that is different.
ASW (American Sport Works) changed names to ALM (American Land Master)
Go to that website and search for the various manuals. They offer a lot of info, for free.
You will find the 6150 series there.

Question: the parts you replaced, how did you determine that they were the right ones?
That rig's age is right on the edge of switching from AC to DC CDI's and from single phase, half wave stators to single phase full wave stators.
Also, the stator and RR (regulator/rectifier) have to match.

Two points to look closely:
1. key switch are known to get water in and corrode
2. The inline fuse holder in photo is horrible. The fuse cap clamps get twisted by the wiring and break the glue loose on the fuse which gives a intermittent connection. Suggest you replace that.

 

[Tomas458Socom]

Your photo shows it as a ASW 6150.
I'm guessing that your reference to Hammerhead would be for the powerplant? There is a brand of machine Hammerhead that is different.
ASW (American Sport Works) changed names to ALM (American Land Master)
Go to that website and search for the various manuals. They offer a lot of info, for free.
You will find the 6150 series there.

Question: the parts you replaced, how did you determine that they were the right ones?
That rig's age is right on the edge of switching from AC to DC CDI's and from single phase, half wave stators to single phase full wave stators.
Also, the stator and RR (regulator/rectifier) have to match.

Two points to look closely:
1. key switch are known to get water in and corrode
2. The inline fuse holder in photo is horrible. The fuse cap clamps get twisted by the wiring and break the glue loose on the fuse which gives a intermittent connection. Suggest you replace that.

I did some work on Pontiac engines back in the day have some knowledge enough to be dangerous lol. we bought a GY6 engine it looked like the best route at the time, I did some research as well hours into looking at things. But still new to this world of micro wheels. We ran into some pit falls. The engine we bought ended up being for a moped I got the smallest one they had (length wise) but it was still for a moped it came with added electrical parts I bought another Stator but not knowing anything about the AC and DC CDI at the time until it didn't start. More research shown the AC DC thing. The four prong plug into the start is showing that it's AC. By the number of wires going into it DC has 4 AC shows 3. That's about as much as I know on the educated guesses lol

 

[electraglide]

............ The Service manual I sent you earlier is for the GY6 150cc engine .... it includes ASW 6150 series. Electrical section starts at page 64........ I take it you ruled out fuel delivery, compression, working spark plug.

 

[Tomas458Socom]

............ The Service manual I sent you earlier is for the GY6 150cc engine .... it includes ASW 6150 series. Electrical section starts at page 64........ I take it you ruled out fuel delivery, compression, working spark plug.

I pulled the plug out and tested it. No spark gonna work that first and if anything else comes up we will get to that as time progresses. Thanks for the manual!! I got it printed out for now

 

[Karttekk]

It turns over but no spark gonna go through and test and ohm out what I can until then. And find out if it's An AC od DC CDI

If the headlights work with the engine not running you have a DC CDI.

 

[Karttekk]

It turns over but no spark gonna go through and test and ohm out what I can until then. And find out if it's An AC od DC CDI

Here is the factory manual for the American Sportworks 6150 electric start buggy/kart. Check the wiring at your stop switches. One is in the dashboard and one is in the black electrical box above the driver's side of the engine. Hammerhead Outdoor Power was bought out by Polaris, you don't have a Hammerhead product. I included a link for the correct CDI.

Go Kart Supply Item 115519 : 150CC CDI ASW

Alternating Current (AC) CDI. Size: Small 1.5

www.gokartsupply.com

https://s3.us-east-1.amazonaws.com/assets.americanlandmaster.com/uploads/manuals/Fun-Kart/6150_ownersmanual.pdf

 

[Snaker]

If the headlights work with the engine not running you have a DC CDI.

The lighting coil is separate from any ignition power coil so there isn't a direct link between the two.
So the China machines could have:
AC lites and AC ignition
Or AC lites and DC ignition
Or DC lites and AC ignition
Or DC lites and DC ignition

 

[Karttekk]

The lighting coil is separate from any ignition power coil so there isn't a direct link between the two.
So the China machines could have:
AC lites and AC ignition
Or AC lites and DC ignition
Or DC lites and AC ignition
Or DC lites and DC ignition

There are two charge coils, one for the lights and one to charge the battery. The ignition power coil isn't related to his question. The power coil on these machines is actually the plug wire. He's asking if he has an AC CDI or a DC CDI. The way to determine this is checking if the headlights work with the engine off. This particular machine shipped with a DC CDI. I've repaired and sold a bunch of these machines.

Ignition Coil for GY6, 150cc Engine | 05906

www.bmikarts.com

 

[Karttekk]

Let me rephrase that. The two charge coils are for Honda clone engines, the GY6 has a "generator" so to speak that charges the battery.

 

[Karttekk]

The CDI is a spark module basically.

 

[Tomas458Socom]

To be honest, there are so many variations of them Chinese buggies out there, that finding an accurate wiring diagram, for your specific kart is probably going to be very difficult, if not impossible.

Plus, the wire & connectors on them are so cheap that, after banging their heads
...& then, pulling most of their hair out most folks just make their own wiring harness.

There are a few guys on here that should be able to help you figure it out.

This is so so true I am almost to the point of rewiring everything myself as well. I knew when my wife bought it it was gonna be a challenge. Finding Correct information is everything. And most of what I gathered on that is that its a crap shoot

 

[Tomas458Socom]

The CDI is a spark module basically.

So what items will I be needing if I choose to wire everything to the AC route, I tried the lights they don't come on with the key at all (maybe they don't even work I don't know ) If I make an educated guess a Voltage regulator, AC CDI, what about the stator does that get replaced as well. SO far the wiring to the CDI shows it to be AC both by wiring and then by the size of the CDI itself. Tried running a hot wire directly from the battery to the CDI as stated before but still no spark. I replaced the kill button as it was stuck in the kill position. The wiring on the diagram doesn't match what is on the cart. Maybe I am looking at it wrong too IDK. I am going to test the stator now and see if that has an issue as its was replaced.

 

[Karttekk]

Do any of the decals say Blue Lightning?