So when the Tecumseh 6HP powersport motor in my Carter spx blew up I decided to replace it with the motor from my kazuma cheetah 200 since I can't find plastic for it anyway. The result so far is gratifying and aggravating. I was able to mount the motor with minimal effort using one of it's original brackets and the kart deck. I haven't started the throttle and clutch linkages yet but I have some ideas about how to keep the clutch at my feet. The brick wall my head is bouncing on at the moment is wires. Lots of them. I know I need the magneto and that little aluminum box thing, but what else do I have to have? I want to keep the safety lights and had hopes of eventually adding the speedometer, blinkers, and brake lights from the bike but considering how many wires and harnesses I'm looking at here I just don't really think it's worth it. It seems like each harness connects to another and I can't remove any single component without leaving an open circuit hanging around. Does anyone have significant knowledge of electrical systems on these Chinese bikes or know of any place I can research it?
dirt bike motor in kart. wiring?
- Thread starter Kuzify
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modelengineer
Lord of the noise
I would definitely use the bikes original ignition. In fact the way I wired my bike engine was just to strip the bike wiring harness of all the lights and unnecessary circuits and extend wires where required.
CAPTAINCAVEMAN
Member
I had to do the same thing. what I did was just take away a wire and see if it still turned over and started until I had eliminated all wires that were unnecessary to start it. there will be wires left coming out of the engine these you should leave and tuck away safely in case you decide you want lights or a speedometer or something later.
Yeah, wish I had thought that far ahead. I have all of the safety crap hooked up. Basically everything but the lights and I can't get it to turn over. Tried arcing the starter and can't get a spark. The really aggravating part is that the bikes original wiring has lots of splices. Is that normal?
All of these circuits intersect eachother. To use one uncut harness is to use them all. I'm wondering, are most bikes of similar size comprised of the same components? Could I possibly use a wiring diagram from another bike? Kazuma sucks for discontinuing a product and not still keeping resources out there for people to keep their junk running. It would really help if I had more knowledge about how it all works. I'm not opposed to completely rewiring it using these same harnesses and making engine removal easier, (have to remove the motor to change the oil), but there are 11 wires coming from the motor. Of those 11, only 6 were originally connected. Six is easier but still too much for guesswork. Please give opinions and advice. This brick wall is wearing me down.
gman3850
Member
so for just key ignition your gonna need wiring wise, magneto, cdi, voltage reg, coil, ignition solenoid, ignition switch, wiring to starter, and cut off switch
picture 1 is wiring from magneto, picture 2 is ignition solenoid, picture 4 is ignition switch, picture 5 is coil, and picture 6 is cdi
picture 1 is wiring from magneto, picture 2 is ignition solenoid, picture 4 is ignition switch, picture 5 is coil, and picture 6 is cdi
anderkart
Moderator
Ok, next step is to check the 2 small (yellow and green) wires going to your starter solenoid.
For that solenoid to engage the starter:
One of those 2 wires needs to get power, and the other needs to be getting a ground.
When testing this circuit, something you need to understand is there's 2 diferent methods your starter-button/starter-solenoid circuit may of been wired on your motorcycle:
The first method would be that your wiring harness supplies a constant ground to one of those 2 (yellow & green) wires at your starter solenoid, and then your starter button would send power to the other wire when pushed in.
Or, its possible that your starter button is supposed to send a ground signal to engage the solenoid, and in this case the other solenoid wire would need to be receiving power when the ignition switch is turned on. If your motorcycle was wired this way, Its possible that your only problem now might be that you simply need to ground your starter button housing, because this might be how this switch receives its source of ground
So I think maybe somewhere between the plastic push button or the ignition I had to drill out cause I lost the key, something is broken. No matter, I did away with both and wired it up to the old starter switch and it turned the starter. On this much simpler switch there are 4 wires; red, black, white, and green. Red is constant power in, black is...kill switch?, white is starter(yellow/red on starter relay), and green ground. My question, where does that black attach to kill. There is a black with white line coming from cdi unattached.
oldbikerarlo
Old guy
Do a goggle search for your moter and electronic schematic, it will show you how few wires you realy need.
Yeah well in the research I've done so far it looks like the motor is a Zongshen. It's a kazuma cheetah 200 but it's also a zongshen sx200gy. So far I haven't been able to find much info other than basic stats. If someone can find some more detailed info out a manual that would be awesome.
Anyway, todayI hooked up the starter switch from the kart and it turned over without a problem. Now my problem is no fire. While I was hooking it up, one of the ground wires hit the positive battery post. Since I did have the negative post connected it did spark. What would that have ruined? It definitely had a spark yesterday but I couldn't get the starter operable.
Thank you all for your help. I know this kart will be worth all the work.
Anyway, todayI hooked up the starter switch from the kart and it turned over without a problem. Now my problem is no fire. While I was hooking it up, one of the ground wires hit the positive battery post. Since I did have the negative post connected it did spark. What would that have ruined? It definitely had a spark yesterday but I couldn't get the starter operable.
Thank you all for your help. I know this kart will be worth all the work.
anderkart
Moderator
I couldnt find any wiring digrams for your model with a 6-wire CDI box, but this diagram might help:
http://www.hooperimports.com/images/Engine_Wiring/Diagram150cc.jpg
Some of your wire colors are diferent, but that shows the wire positions at the CDI box plug...
You could also check out some of the wiring diagrams at this google image search link too: http://www.google.com/search?q=zong...or.r_qf.&fp=5c5c88cd6a58f079&biw=1024&bih=532
http://www.hooperimports.com/images/Engine_Wiring/Diagram150cc.jpg
Some of your wire colors are diferent, but that shows the wire positions at the CDI box plug...
You could also check out some of the wiring diagrams at this google image search link too: http://www.google.com/search?q=zong...or.r_qf.&fp=5c5c88cd6a58f079&biw=1024&bih=532
Awesome! That image search definitely helps with the CDI wiring. This is the exact CDI I have.http://www.kazumaracing.com/pin-cdi-wire-diagram-pi-17777.html
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