This darn electric system!!!

[TheDudeWithTheDeuce]

Hey everyone,

I bought a junkyard Manco deuce from a neighbor's junkyard about a year ago, and me and my dad took it home and got it running because it has got the best engine ever!!! A 18HP Honda v twin it has never stalled on me through the many times I have gone offroading. Never have had any problems with it. But to the point, the electrical system is kind of a mess and the ignition does not work so we have to hotwire it. Just a few days ago, I added a little button on it so I could have a push button start, but it did not work so I just left it alone. Just yesterday I went out to start it but when I crossed the 2 bolts, nothing happened. The starter did not move or anything.

 

[Budget GoKart]

I have the Honda gx390 used it is amazing they are work horses and will run all day and nigfht if they have gas my yerfdog is the most reliable out of my fleet plus is starts first pull every time and that wiring is a mess

 

[Budget GoKart]

Take some pictures of the key start and I can help if it is wired like a lawn mower
There is a wire to the coil (kill)
A wire to the solenoid (start)
A wire to the battery (power)
And a wire to ground from the key
Those are the only ones that matter any others are accessories. Your key switch should have letters labeled or you can get one at an auto parts store

 

[TheDudeWithTheDeuce]

It has 5 contact points(I think that's what they're called)

 

[TheDudeWithTheDeuce]

It has 5 points of contact

 

[Budget GoKart]

Each one has a letter
G ground
S solenoid
L lights
M magneto (thingy that makes spark I think)
B battery (this one needs power so directly to battery)
trace those wires and get rid of the rest if they aren't connected to something important.
Remove all zip ties take and anything on the wires and that will help a lot trust me

 

[Brianator]

Solid advice if you ask me!

 

[TheDudeWithTheDeuce]

I took this part off was well. Could this be the problem possibly? It it a voltage rectifier/regulator. I found one on eBay for 50 bucks.

 

[anickode]

I took this part off was well. Could this be the problem possibly? It it a voltage rectifier/regulator. I found one on eBay for 50 bucks.

If that was broken, engine would run if jump started, but it would not charge the battery.

 

[TheDudeWithTheDeuce]

What about this part?

 

[Budget GoKart]

That is the starter solenoid if you can get one at most lawn mower shops or eBay any solenoid is fine I put a quad solenoid on a lawn mower and it worked better than stock

 

[anickode]

If the solenoid was bad, or the wiring to it was broken, you'd have been able to start it by jumping across the 2 large terminals with a screwdriver.


The electrical system as a whole appears to be a huge mess. Wires and splices all over the place... Perhaps a roll of primary wire and some good crimp terminals would be a good place to start. Sort out that rats nest before you start throwing money at it.

 

[TheDudeWithTheDeuce]

I have 1 fuse on here as well, could that do anything?

I opened up the ignition and some or the wires around it had burnt through the insulation, so I wrapped it up with electricians tape and put it back.

Could either of these be causing a problem?

---------- Post added at 08:53 PM ---------- Previous post was at 08:20 PM ----------

I found some places were there were patches of bare wires, so I wrapped them up.

The screw that connects the negative battery terminal to the engine is stripped and does not hang on, it just sits loosely on it.

Could any of these be the problem?

 

[anickode]

Literally all of these things are problems. That's why I suggested getting a roll of wire and some good terminals and start fresh with a new wiring harness.

I had to do that when I bought my tractor. Well worth the time and effort. Redid the entire harness to the OEM color code and wiring diagram. Got rid of a LOT of gremlins that way.

 

[Brianator]

More solid advice! You guys are awesome!

 

[TheDudeWithTheDeuce]

Again, I'm only 12, but this go cart is pretty simple and I understand a simple circuit, so I will see what I can do about new wiring. I totally agree with you. Thank you again for all your help!! Especially to Anickode. I really appreciate all the advice!!

 

[anickode]

Again, I'm only 12, but this go cart is pretty simple and I understand a simple circuit, so I will see what I can do about new wiring. I totally agree with you. Thank you again for all your help!! Especially to Anickode. I really appreciate all the advice!!

If all the wires are still actually connected where they belong, it should be pretty straight forward. Replace one at a time, taking care to make sure everything is the right length so you can bundle it nearly when it's done.

They sell butt splices and crimp terminals with heat shrink tube attached to them... They're not super cheap, but they are REALLY good. Just squish and heat. Get a good crimping tool too. Again not cheap, but it's something you'll keep in your toolbox and use forever.