Fixin' up a Redcat (antoher Chinese knock-off quad)

[supermanotorious]

This thread will be dedicated to the quad I'm obligated to fix for the neighbor that gave me the Zongshen. I'll get pictures up soon so please be patient with those. It's pretty doggone similar to the Zongshen but definitely has differences. So tonight I got down to some basics since he would like to take it out for Memorial Day.

The battery is totally dead so needs replaced, I bought a new one for the Zongshen so I put in the Redcat and the good news is we have a good starter, good compression, and some working lights. The bad is no spark. Just as with the other, could be a safety switch or bad CDI. I will cut the kill wire and see if that gives spark- if not then I'll probably just order the CDI. That sucks because I ordered a 6-pin CDI for the Zongshen then didn't need it. The Redcat- a 4-pin CDI of course.

The fuel smells horrible so a carb cleanin' is in the forecast for sure. Pics and updates coming soon!

 

[supermanotorious]

can anyone tell me which wire is the kill switch on this 4-pin? google isn't helping too much

 

[supermanotorious]

hnmmm, maybe there isn't a kill wire?

 

[firemanjim]

Does that help?

 

[supermanotorious]

I think we have a match! Thank you!

 

[supermanotorious]

well the tires seem to be holding air which is good.

with all the projects I have I honestly want to do as little as possible to get this thing running and give it back to him.

the wires are pretty butchered and who the heck knows why, the wires from the CDI to the coil are torn (yes- torn) and exposed, touching each other, I separated them and tested with a meter while attempting to start, no voltage so I'm thinking maybe the CDI was fried, I ordered a new one but still need to confirm that voltage is getting to the CDI

there are several other sets of torn wires, a couple I believe to be indicator lights, then a couple I'm really not sure about

it would be nice to see the wire map specific to this bike

 

[supermanotorious]

I don't really understand the killswitch wire, since it says "Goes to Kill Switch and then to positive battery terminal"

Would I see 12v+ on that line when the clutch is pulled in and the rear brake is engaged?

Does that help?

 

[firemanjim]

I don't really understand the killswitch wire, since it says "Goes to Kill Switch and then to positive battery terminal"

Would I see 12v+ on that line when the clutch is pulled in and the rear brake is engaged?

Hmmm good question! Let me go look at what I got outside. That diagram don't look right.

 

[noiseguy]

Those 4 post cdi units are incredibly common. See them on Honda scooters, fer instance.

All the kill switch does is cut 12v power to the cdi. This effectively shuts off the cdi and motor. Ensure you have 12v at that terminal and ground is connected. Otherwise swap new good part to see if issue is addressed.

 

[noiseguy]

I don't really understand the killswitch wire, since it says "Goes to Kill Switch and then to positive battery terminal"

Would I see 12v+ on that line when the clutch is pulled in and the rear brake is engaged?

Yes. Yes you would. You should see it anytime battery is in bike and bike is switched "on".

 

[supermanotorious]

I cut that wire before I asked about it, I can easily solder it back, BUT, while disconnected, should I still see 12V?

EDIT:

Sure enough, I got 12V! So I fixed the torn coil wires and..... SPARK! So again, a new CDI not necessary. Here's even better news: I finished cleaning the carb, put fuel in the tank, and she fires up!! But only with choke on so I think the idle screw needs adjusted. That's still a tough call, no telling if it has been tampered with or not

Picture 1 shows where I fixed the coil wires
Picture 2 shows what I believe to be the headlight wires
Picture 3 shows wire that I'm not sure of- what else would be up near the front?
Picture 4 is the tire size in case I need to replace
Picture 5 shows the Neutral indicator wire and what I believe to be the Reverse indicator, the N wires are torn but tested positive when I shifted, the R has a holder and bulb but I think the bulb is bad

Also the cooling fan never kicked on, the wires are intact. Not sure if there is a thermostat or sensor on this bike.

 

[noiseguy]

Disconnected from what, the cdi? Yes, you should. Why did you cut it?

 

[supermanotorious]

I thought it was similar to the 6 PIN CDI that it had kill switch "in" and separate 12v "in", was trying to see if it was a safety switch issue. Totally moot point now

 

[supermanotorious]

ah ha! after studying my ZOngshen, I determined the mystery wires must be hi(or)low for the headlights!

pic 1 is zongshen
pic 2 redcat, I didn't notice those wires came from the same place

 

[supermanotorious]

Again I stand corrected. I was pretty tired while posting last night. The mystery wires are actually part of the indicator light bundle BUT the shroud only has 2 indicators so what could that be?

What are people doing to replace headlights? I don't think $50-$60 per assembly is very cool.

 

[supermanotorious]

resources:

general specs- http://www.racewayatv.com/redcat-vx-200-cc-atv.php

generic parts- http://www.kazumapartsonline.com/

generic parts- http://www.chineseatvpart.com/

generic parts-http://www.partsforscooters.com/ATV-Parts

generic parts- http://www.parts4kazuma.com/yamoto-parts-c-1_145_208.html

generic parts- http://www.roketapartsonline.com/

generic parts- http://www.monsterscooterparts.com/off-road-atv-parts.html

 

[noiseguy]

If engine idles only on choke, carb idle circuit is likely plugged. Find idle jet and clean.

 

[supermanotorious]

decent video on this style carb

https://www.youtube.com/watch?v=-2NIDcqv59I

 

[supermanotorious]

ugh, the intake manifold has a huge crack and totally over rules the idle

 

[noiseguy]

ugh, the intake manifold has a huge crack and totally over rules the idle

Yep... That will do it too.