Any need advice on starting problems

[MajorPatton]

So i bought a go kart about a month ago, i have since repainted it, replaced the seat, replaced the solenoid, and replaced the battery and the headlights. My current peoblem is that the key doesnt do anything, however if i jump the solenoid i can get it to turn over ( not start ). Before i replaced the solenoid i could get it to start. Im pretty new to all this and this is a learning experience, so any advice would be greatly appreciated. Also of anyone knows what this kart is, let me know, looks similar to a honda fl400 pilot.

 

[Joe-405]

It sure sounds like you wired something wrong when you reinstalled everything. A pic of the engine and the key switch would be nice.

Any loose wires on the key switch anywhere ? The wire that lights up the test light when you turn the key to the spring loaded return position is the one your after.

 

[MajorPatton]

Hard to get a pic of the engine

 

[MajorPatton]

Is also has a badge with a vin number and a manufacturer, but i cant find anything on it.

 

[Joe-405]

On that switch it has markings on it.

Acc
Start
And maybe grd or ground

Follow the start wire. Should go to the solenoid to activate it.

Test light on the start pole and try starting it should light up also whil in the spring loaded position.

 

[itsid]

I suspect the solenoid being installed incorrectly tbh..

SOOOO

Solenoid has four wires (sometimes just three but bear with me for a second)

TWO are the actuator that has one ground and the positive wire from the key switch.
(ground can be directly routed via the chassis, so paint can cause it to not work properly!)

the bigger* TWO are the actual Power, both are essentially positive if all goes well.
ONE of which goes directly to the starter motor,
the other directly to the battery (fused usally)!

* bigger because most if not all solenoids have screw terminals for these lines, in order to mount nice big beefy wires, since it deals with serious amperage
the other two are usually just a simple flathead terminal (or cable connector)

Please post a pic of the solenoid as well, just to be sure

'sid

 

[MajorPatton]

So i just wired the solenoid the same way the previous owner did, so it could very well be wrong. As you can see i have it wired to the battery and starter, then the yellow and green wire run off into who knows where, and the red wire is coming from the ignition.

 

[Joe-405]

So does the red wire light up when the switch is turned on to start with a test light ?

Sid has the correct ideas also on what to check for. I like to start simple then work my way to the harder things. Seems to help people that aren’t electrical kart oriented easier.

 

[MajorPatton]

Ive got to find my test light, ill update once i do. Thanks

 

[itsid]

thanks for that..
And I think I see your problem..

bare wires, open free floating spade connectors.. all carry ~12V..
the slightest touch against the engine, the chassis or interconnection between two
and you'll have a problem.
What you need is not a test light, but a multimeter.

Find a Multimeter, set it to it's highest possible ampere reading
key switch to "OFF"
remove the ground wire from the battery, but one test lead on the battery terminal and the other one on the wire..
if you read anything but zero you have a creeping current you MUST get rid of!

Your wires in general seem to be in very bad condition.. chances are one's cracked
and that's why the engine barely turns over but wouldn't start when you jump the solenoid.

I'll leave you with Joe for now, although I would do things very differently...
but I'm reasonably sure you can trace the issue down following his' advice,
and it's better to not confuse you with my different approach for now

In the unlikely case it fails, I call dibs on the next try

For now: Good luck!

'sid

 

[Karttekk]

Can you provide the manufacturer from that plate you mentioned? Maybe we can find some information for you that way.

Thanks

 

[Karttekk]

This basic diagram may help. Source: RH Detox Design

See if this helps.

 

[S S]

Hey i'm putting some suspension on my go kart you mind showing some images of your set up that i could go off of?

 

[MajorPatton]

Ok so the multi meter is reading zero on both wires, i found my light tester, and it lights up on two of the three terminals on the ignition. The company on the badge is Bumwoo co. and is made in korea. And here is the front and rear suspension.

 

[itsid]

Company is now called BumWoo Precision Co

Contact them with the serial number of your kart over facebook to get proper ID and information:
https://www.facebook.com/pages/biz/BUMWOO-PRECISION-CO-LTD-South-korea-1379291275427543/
or over their webpage:
http://www.bumwoopic.com/eng/customer/inquiry.html

And you are correct, there's little to no info about their karts on the net.
I know they started the Go Kart business in 2002.. but I'm not even sure they still make karts at all..

'sid

 

[Joe-405]

So most of your 3 pin ignition switches are as follows on a gy6 based............

Functions of each pin

I. CDI Pinot (ignition box)
II. Ground
III. Starter Relay (Solenoid) this one shouldn’t be lit until the key is in the start spring loaded position.

Switch position function

OFF :: I and II open internally, interrupting CDI ground.
ON :: I and II close internally, allowing CDI ground.
START :: I and II remain closed. III and II close, allowing starter solenoid ground.


And you can get full wiring harnesses with switches and everything off eBay for $50 if you would like that route also. Just make sure it matches your engine numbers.

---------- Post added at 07:12 PM ---------- Previous post was at 07:02 PM ----------

On your kymco engine you have some numbers. It will help us also.

It will be 3 numbers then 3 letters.

There are diagrams online you can use those numbers to find the right wiring setup for your engine.

 

[Karttekk]

Once you verify you have a GY6 engine, you might be better off getting a complete wiring harness, CDI, key & cylinder, magneto and whatever else is needed rather than spend hours trying to fix it. I'm sure there are kits that pretty much replace what's there. Tough call looking for information on an unknown or obsolete product. I usually suggest sticking with Trailmaster or Hammerhead karts due to support and part availability. Not saying you can't fix it, just thinking of alternative solutions.

 

[MajorPatton]

The only thing i can find on the motor is KHE7.1, however i have yet to find much on it. I found someone selling one that looks the same, if it is the same motor then it is a 250cc. Ill keep resererching and see if i cant find a witing hraness for it.

 

[MajorPatton]

Allright, i dug around, found a wire that wasnt connected, and now the ignition works, however it looks like the spark plug is bad so im goong to replace that. Just a quick update for anyone who cares.

 

[itsid]

we still care but there wasn't anything we could contribute ATM..

thanks for the update!

'sid