DONGFANG DF200GKD Gokart help???

[Karttekk]

Just an update, I got everything to work now. Sometime you just gotta double check things. I used a volt meter and test out each wires make sure their is power and was able to figure out the issue.

I suggested a similar diagnostic procedure when you first posted your question back in November I think it was. A test light or multi-meter is your best friend when dealing with electrical concerns. Glad you figured it out.

 

[Dang]

I’ve been at work in Louisiana, sorry. When I get home if you still need pics I can take some and post them.

Yes that will be great, I still trying to figure where that wire connected to. Thanks.

---------- Post added at 08:37 AM ---------- Previous post was at 08:27 AM ----------

I suggested a similar diagnostic procedure when you first posted your question back in November I think it was. A test light or multi-meter is your best friend when dealing with electrical concerns. Glad you figured it out.

I test it out the last time on all the wires and was just stuck. I went back again this time thoroughly with every wires and figure it out. You were right the multi-meter really help out a great deal. Thanks for tip.

 

[Denny]

Run a separate ground wire from the battery to the starter. You may have a battery on its last leg. Or it could be a starter that has pooped the bed.
How is the water in the battery? Well that should help out some.

 

[Denny]

You probably have a battery That is the bed. Take it to Autozone. Advance Auto or O ‘Reilly’s and have it load tested.

 

[madprofessor]

Advance Auto Parts just tested my van's battery a week ago. Looked good at 12.3 volts on a 12 volt-battery, but it read out battery weak and needs replacing. Don't be fooled by one of those testers, they get used for a reason, when you can't be sure about a battery. 12.3 volts is NOT GOOD for a 12-volt battery, should be about 14 volts. Even a 1.5 volt AA battery in your TV remote will read about 1. 65 volts when new.

 

[Rexfranks]

Yea that's the first thing I did. I even unscrew the wiring on the back of the front brake fluid pedal and short the 2 little wire together still didn't work.

I'm having the exact same problem and same buggy what did you do to fix it

 

[madprofessor]

Backwards sounds backwards, but it's one of the two ways to go on an electrical diagnosis (other way is forward). Start at the tail end and work backwards this time. Pull the starter loose enough that the gear doesn't engage the engine, and try it. If it spins, it's a weak battery or an engine problem. Or even a bad starter, but be sure with a new battery to jump it with first. If not, keep working backwards.

 

[rrdelano]

Since you have the same gokart maybe you can help me? I have a black wire in the front of the go kart under the display with connector at the end but it not connecting to anything. The wire is just hanging. Can you check and let me know what connection that wire is attached to? I post a picture of the wire.Thanks.

I have the same wire on mine that's not connected. Did you find out what it goes to?

 

[Richard K.]

Ha everyone well I'm back with a new ? about this DF200GKA It stopped running all it would do is idle you give ti the gas and it would shout off one gentlemen said to replace the carburetor so I did and know it dose the same thing any body have any other thing please let me know
Thank You Rich K.

 

[Karttekk]

Ha everyone well I'm back with a new ? about this DF200GKA It stopped running all it would do is idle you give ti the gas and it would shout off one gentlemen said to replace the carburetor so I did and know it dose the same thing any body have any other thing please let me know
Thank You Rich K.

Sounds like a lean condition. Did you replace the carb gaskets with the carb change? The intake manifold under the carb could be cracked. Take it off and check for cracks. Change the fuel filter if there is one. If there's a fuel valve under the fuel tank make sure it's working by applying vacuum to it. Start it up and spray carb cleaner around the base of the carb. If the RPMs change you have an air or vacuum leak. Check any vacuum hoses for cracks, especially where they go over a nipple or fitting.

 

[Richard K.]

Karttekk, Well thank you for the suggestions but ya that didn't work, I'm about to give up on it. It's got to be something simple but I haven't got it yet. It will idle but when you give it the gas it acks like it going to bog out. It doesn't idle like it should like it's missing
Well if any one have any ideas please write
Thank You, Rich. K.

 

[Karttekk]

Do you have a vacuum pump? Take the fuel hose off the carburetor, attach a vacuum pump to the vacuum port at the fuel valve under the tank and apply vacuum to it. Fuel should flow from the valve and out of the hose. This will eliminate the fuel valve as the culprit. You're not getting enough fuel it sounds like. Another thing to try is removing the fuel valve and running a straight fuel line from the tank to the carb. This takes the fuel valve out of the picture. Pretty simple concept. When you start the machine, vacuum opens the fuel valve and allows fuel to flow to the carb. If something isn't right there, the kart won't run. See if there are any motorcycle shops near you willing to check it out.

 

[snag]

Just an update, I got everything to work now. Sometime you just gotta double check things. I used a volt meter and test out each wires make sure their is power and was able to figure out the issue.

Just curious, what did you find wrong? I have a DF200GKD that I built for my grandson 6 years ago, when he was 13. After he got his license and a truck, it's been parked for 3 years so I've brought it back home to fix. I've got power at the dash when I turn the key, all lights work, but I have to jump it at the solenoid. I replaced the ignition switch and the solenoid, but when I turn the key, it's still "zip". I've been all over this thing with my tester and can't identify any faulty wires. I thought maybe you found something I've overlooked.

 

[Karttekk]

Connect your 12V test light to the power feed side of the solenoid post then turn the key to START. Does the test light illuminate? If it does you're getting power to the starter. If it doesn't, keep probing the hot wire from the solenoid to the key switch to see where you're losing HOT. Do the wire colors match from the key switch to the harness? I've had to re-pin the wires in the key switch to match the harness more than once. Red in the switch should match red in the harness and so on. What about the brake safety switch mentioned earlier? Have you eliminated that? The last problem I had like this was the wires were mismatched in the new key switch. I popped out the wires with a small pick then re-inserted them in the holes that matched the male end of the harness. Run a new wire from the START post on the key switch to the power feed side of the solenoid then try cranking it.

 

[snag]

Connect your 12V test light to the power feed side of the solenoid post then turn the key to START. Does the test light illuminate? If it does you're getting power to the starter. If it doesn't, keep probing the hot wire from the solenoid to the key switch to see where you're losing HOT. Do the wire colors match from the key switch to the harness? I've had to re-pin the wires in the key switch to match the harness more than once. Red in the switch should match red in the harness and so on. What about the brake safety switch mentioned earlier? Have you eliminated that? The last problem I had like this was the wires were mismatched in the new key switch. I popped out the wires with a small pick then re-inserted them in the holes that matched the male end of the harness. Run a new wire from the START post on the key switch to the power feed side of the solenoid then try cranking it.

Thank you.
Yes, I had re-posted the wires in the switch, and everything worked on the dash but the starter wouldn't turn over when I turned the key. I saw what you said, I went back and read all the threads again, and wouldn't you know. I read, "Did you step on the brake pedal?" Works like a charm and I've been messing with this for over a week.

When I built this thing 6 years ago, I gave the manual to my grandson, who has no clue what he did with it, so I'm rebuilding blind, but making headway.
Thanks again. You've been a lifesaver.

 

[Karttekk]

That's great news. Now it's time to hop on that kart and enjoy the heck out of it!

owner′s manual | Manualzz

manualzz.com

 

[snag]

Thank you
I've still got several weeks before I get to that point. I have to replace the brake calipers, rebuild the front end, weld the the frame, realign the engine frame so I can put the motor mount bolt back in, install new front fenders/frames, overhead lights, and repaint it.
You can only imagine what a 13 year old and friends can do over 3 years in the woods and power line roads.

But thanks to you, I'm one step closer

 

[snag]

Where can I find front calipers for my DF200GKD go kart? I've found a couple sites but they are either out of stock or only have the right side. As I'm looking at these sites, they show what appears to be the same caliper pictures and they range from 63mm - 65mm. In the pictures they will show measuring inside to inside, center to center, or outside to outside, which makes me think they are all the same but not sure. I don't want to waste time ordering stuff that doesn't fit.
Thanks

 

[warrior5delta]

Just an update, I got everything to work now. Sometime you just gotta double check things. I used a volt meter and test out each wires make sure their is power and was able to figure out the issue.

So, what was the issue?

 

[srb]

Just an update, I got everything to work now. Sometime you just gotta double check things. I used a volt meter and test out each wires make sure their is power and was able to figure out the issue.

So what exactly was the issue or the wire in question?