Go Kart 150 Basic Wiring Harness How To
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- Опубликовано: 6 мар 2020
- In this video, I will show you how to rewire a 150cc go kart with a wiring diagram, from scratch. That will include, how to use a multimeter, identify all parts, and make the test as I redo the wiring harness. I will follow my electrical plan / wiring diagram I make, and the link for the information is in the description if you want to follow along. This is the basic plan to start the machine. I did not include headlight, speedometer, and accessories, as they are not needed to start your machine. I will make a separate video for that.
You can also BUY the plug-and-play version of this WIRING HARNESS: gokart.maximum.parts/basic-wi...
This is suitable for almost all 150cc go kart including:
Ace Maxxam 150
Carter Talon 150
Hammerhead 150
Trailmaster 150
And any go kart that come with a GY6 150
Electrical Plan / Wiring Diagram and information available on our website: info-gokart.maximum.parts/how...
Facebook: / maximumparts
Instagram: / maximumparts
Go Karts Parts Canada: cad-gokart.maximum.parts/
Go Karts Parts US Price: gokart.maximum.parts/ 
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If you are looking for the plug-and-play version of this wiring harness, watch this video instead: ruclips.net/video/dXP3SFopKVY/видео.html
You can also BUY the plug-and-play version of this WIRING HARNESS: gokart.maximum.parts/basic-wiring-harness-gy6-150.html
Excellent tutorial. I've just completely refurbed my buggy. Had to scrap all the wiring. Your video has helped ne no end. Good job.
Great explanation makes this work well for a wide variety of small vehicles. Filing this away for next time I have electrical problems. Thanks!
this was a very helpful video for me i have a 2009 yonghe 150cc engine on my go cart and had to buy a new wiring harness but not everything was connected together the same way as the old harness so watching this helped me figure out where everything needed to go thank you for the step by step prosses
So happy to have stumbled on this !!!😊 Familiar and comfortable with mechanical, and 12V electrical systems.
Not at all familiar with cdis, regulators, etc...missed
Got a 250 GIO buggy recently and wiring was ripped up everywhere, watched many many videos on where to start....what to test....what goes where..... You Sir! Have the most comprehensive,clear, well narrated video to explain the entire works of the system I am perplexed by right now. I will face this feat soon, and am much more confident and confident of how to tackle and get it running! Thank you very much for the video 😁
Happy it will help. Some parts are a little bit different on the Gio 250 but the principal is the same. If you have experience in electrical and mechanic, you should be able to get it done. One wire at the time and you will get it. It will take time but you should get it.
Again, thank you for video and clear explanation of what's going where. Using your video for knowing now what plugs into what and where and measuring the resistance of each wire so far is working great and getting closer one wire at a time😁
@@maximumparts I really want to order your wire harness but I cannot find it on your website
@@maddgamingstudios4859 Sorry, I don't. The problem is every wiring harness are different. So any wiring harness you will buy will need to be modify unless it is specific for your machine. The only thing I have is the wire and connectors to help you rebuild. This is the link for the wire: gokart.maximum.parts/catalogsearch/result/?q=wire and this is the link for the connectors: gokart.maximum.parts/catalogsearch/result/?q=connector
Thank you very much, your video is very straight forward i like the way you explain every part of it and even with more emphasis on the key parts. Its a nice job, looking forward to see more videos on how to connect the other accessories including the lights, i will make a follow up on this. From Kenya in Africa.
Thanks. The key switch is a common problem for many people. This is why I spent more time on it. The point is to help as many peoples as possible.
This is the first tutorial that I have really understood after watching dozens of useless explanations This is brilliant 👏 👌
Thank you
You have no idea how much this helped me . Thank you so much
I look forward to the accessories video. This video itself is really helpful.
Great video. Excellent explanations and allowed me to just make my own harness just one wire at a time. Go kart fired right up.
I'm happy the video helped you!
By curiosity, how long did it take you to build your harness with the help of the video?
@@maximumparts I didn't do it all at once, definitely took some time. Probably somewhere between 6-8 hours, but I'm not a pro. Someone who's experienced working with atv's, motocross or go-karts should be able to do it in less time. I have some understanding of what I'm doing, but mostly I'm just a dad who's not afraid to try to fix things, especially the go-kart because my kids love it.
i love the actual explanation like it should be.. thank you great video
thanks this is really helpful.. now i have my buggy doesn't look like it has a medusa in the back now that i fix all the wires and all the electric components .. thank you so much
Glad it helped. Now that it's fixed, is there anything in the video I could of make better and easier for people to understand?
This is an awesome well explained video. My son has had a gy6 kart that hasn't run in 8 years. I bought a new stator as he had no spark. It has just been sitting. Now I plan to get it up and running.
Excellent tutorial!
AWESOME explanation!! Thank you!
thanks man this is the best video i have found for this would love one to check the stator too bc you make it easy
Thanks. The plan is to go through the entire electrical system and show people how to connect it. Also, make videos on troubleshooting and test everything. Split things in-group like the charging system, CDI, and every component. Yes, the stator will be part of it.
I have the same style Kart ! but in a two seater that I'm working on. I am in the process of testing the ENG today Oct. 18 , 2020. i have no idea How any thing works but after seeing this video i think i can get mine running if no electrical component are burned out fingers Crossed. I picked up the Go kart up from a friend 3 hours away for 200 $ =-) =-) =-) very happy btw. i hope i can get her running big THANKS to you Sir. I'm a Automotive TECH and this is very simple you help me Identify each part correctly. VERY COOL VIDEO
Okay so the eng has no spark and the starter will not turn the motor but the starter works it turned the motor over a few times and stop spinning the motor . So what I am going to do is put a 212 cc with a torque converter 30 S . So what I will be doing is Flipping the axel and welding a new plate to the Frame .
That’s helping us a lot. Thanks so much.
Thank you so much for taking the time. Tres bien.
So I have a go kart that is very similar to yours in the video. It ran great. Sat over the winter and battery died. I replaced the battery and as soon as I hooked it up the engine kept turning over. Without they key even in it. I tried replacing the ignition switch and starter relay. Any idea on where to start? I just ordered a rectifier and CDI. After watching the video I’m thinking may be a bad ground. Not sure. Any help would be much appreciated, before I just try to completely re wire it. Which I’ve never done so it may cause more problems.
Excellent video!!!! Thank you for sharing this video.
very well done.. u have the best wiring video i have seen.thanks much
The first 50 seconds of this video fixed all my problems. Thank you so much for this video, my kids can get back to the kart.
By my kids I mean mainly me.
Well done!!!
I really appricate your video it helped me so much. I did have a problem with the cdi it kept blowing up and I still have not solved the issue but I believe it because it was a AC CDI and I just bought a DC CDI. Hopefully it works.. new motor was installed 2004 hammerhead twister.
hi, did the DC , dct work ? thanks
You my friend should teach electrical systems at a community college ! Definitely one of the best ignition system explanations I have seem on youtube. I have a 5-wire yerfdog CUV ignition which I am troubleshooting but I think this will help get er' done ! THANKS FOR THE AWESOME TUTORIAL !
Thanks, happy it help. I don't have any 5 wires ignition switch machine. I do have some 5 wires switch, from what I see there's 2 types. 1- When you turn the switch off, it stop the CDI if you have an AC CDI, 2 of the wires short the CDI signal. 2- When the machine run they use 2 wires of the switch to give more power, they use the wire coming out of the regulator + 12 volts and give more power to your circuit. The 3 basic wires I have on my video are also on those 2 switches.
Did you ever make the video for the lights?
Thank u best in depth video
If I have a bad ground will my little red power wire with the fuse heat up?
This is a great video
Hello, Max Parts. I took apart my flywheel cover to diagnose a no spark no start situatuon, and it turns out that the thing that connects into the 5 wire gear position sensor looks fried, and one of the sensors is fried as well. What can I do in this case?
Change the stator. You need to find why the stator goes bad. Might be because you have a short somewhere or you are using more power than the stator can produce with high power lights or something like that.
What is the main difference with my ac cdi should basically just be the red/black going to stator instead of ignition correct? Could I follow this diagram for the rest
If you only change the CDI parts of it, yes all the rest is the same. Check for the wiring diagram for an AC CDI and check the difference. Would have to check and test it first to give you an answer.
All grounds are good and I'm getting 12v at the fuse/starter relay but not at the key or starter when i turn the key, why would I not be getting anything at the key? I've had this issue on and off.
You should have 12 volts on the red wire. If you don't, it mean you have a bad wire between the battery and the ignition switch. If the red wire have 12 volts. When you turn the key to the first position, you should have 12 volts on one more wire. When you turn the key to the start position, you should have 12 volts on any wire. If you do not have any power coming out the switch, it mean your switch is bad.
Hey brother. Still having problems with ignition to start engine. Won't engage starter ??? Power but stops at solenoid.??
Hey i got a question do i have to use the brakes to start my trailmaster because i rember hearing a click when i press the brake to start it. But it was sitting for a long time and i bleeded my brakes and ever since i couldnt get it to turn but the lights blinkers ds and horns work
@Moo2k Check if you brake light become brighter when you push the brake pedal. If not, your machine won't start. the way it work is, on the master cylinder, you have a brake switch with 2 wires, when you push the brake light, the brake light become brighter and it also engage a relay under the dash. When the relay engage, it connect 2 wires together that will let you use the starter relay. If the relay does not engage, there's no power to the starter solenoid and won't start.
1- If you want to test something, you can turn the key to accessories / first click. On the starter relay, there's 2 bolts on the top, if you touch them with a screwdriver or piece of metal, it will engage the starter. Just be careful and wear protective gear to be safe. Electricity can be dangerous.
2- If you bypass the relay under the dash and connect the 2 wires that goes in the back to the solenoid, you won't need to push the brake anymore. The problem is, if the machine is not perfectly tune and the engine rev higher than usual, the machine will start moving. Again, be careful.
3- If you remove the 2 wires from the master cylinder and connect them together, it will act like you push the brake pedal. The down side of it, people behind you will think you always push the brake and can be dangerous again because they won't see the you psh the pedal or not.
Bottom line, it is probably when you bleed it. The switch on the master cylinder is touchy. I have similar problem when I bleed my machine and the switch didn't work after. Causing the same problem you have. You might have air between the master cylinder and the switch and it stop working.
Thank you so mutch👍👍
I have a Hammerhead GTS 150 and i had to get an aftermarket ignition key switch . I have 3 wires a red, green and a white wire. The red and green wires come from my battery. The new 3 wire ignition key switch has the letters B, S and M on it. What color wire goes to what letter?
Where did you get the switch?
Did it come with an electrical plan that explain what goes where?
This is the link for the ignition switch for a Hammerhead GTS 150: gokart.maximum.parts/hammerhead-150-250-ignition-switch-3-wires.html
Why you have to change it for a different one?
At 30:50 you show the stock harness coming from under the plastic dash cowl and the Black, Green and Yellow/Green wires are right there! Those are what goes to my ignition switch. Did you bypass the stock harness with new colors? The Red, White , Green?
do you have a simular vidio w/ 150cc chinese AD-CDI
is your wiring harness has a push botton or just the key switch? coz i need help for my GY6 engine 150cc? thanks and waiting from your reply
In the video I made, there is no push button. In my case it's the start position on the switch that start the engine. In your case, your switch should only get one position to power everything. The start button should be connect at the power on of the switch and instead of turning the key to the last position, you will push the start button. It is the same principal.
Where do you connect the wire from the starter?
Thanks for video
Nice video 👍
Thanks 👍
Where can I find the wire harness at
whats the resistor for or hooked up to?i must have a lemon cuz it wont fire,very frustrating cuz ive tested the whole system,i took all the acc crap off,regrounded and soldered all joints and shrink wrap,unhooked the killswitch,i guess ima have to just buy a hole new harness to see if it even runs,it was doa and sitting for years,you made very good informative video
One side of the resistor connect to ground, the other side connect to the enricher. The other side of the enricher connect to the yellow wire from the stator. The enricher is one the carburetor, it give you more gas when you start the machine. This is the opposite of a choke. As the engine warm up it close a needle / entry of gas. I have doubt this is your problem. The engine will start for a minute or so before you have problem. As the engine warm up you will have too much gas coming in and the engine will die or be hard to run.
Did you check the spark like I do in the video?
You can follow the video, in my case I plug wires and test. In your case, you need to find the wire and test it.
You need 3 things to start an engine, spark, fuel and air. Soon you have all 3 it will start. Go by elimination.
As for buying a wiring harness, you will have the same problem is the wiring harness is not compatible at 100% with your machine. You will have to make it work ...
Its my coil pack supposed to have two grounds?
This video was very helpful and I did exactly the same as you did but I have no spark. I hope you can help. Thanks
Thanks. If you did exactly the same and you have all the same components we use, this is the only thing left. You have a bad spark plug, CDI or ignition coil. Soon one of them is bad, you won't have spark anymore. This is the 3 most common one. The last thing and less common will be the pick up coil. Unfortunately, we didn't do the troubleshooting video yet but will do eventually. Subscribe and you will be notify when we will put new video on RUclips. This is the basic video on how to connect everything, there's more to it and we will also split them by section to make it easier for people.
How would you hook up a 11post stator for this engine
This is a kit we have: gokart.maximum.parts/3-phase-rectifier-regulator-stator-11-poles-upgrade-kit.html You can add the wiring harness with it to make it easier to connect everything.
You need to change the stator and regulator to make it work. You need both to be compatible.
Really great video, incredibly useful. I've got an AC CDI so it's a little different, but a lot of the information is still relevant. What size fuse is used between the battery and the rest of the circuit?
Thanks. The fuse is a 10 amps. The battery is also 10 amps. The fuse is mainly there for a short, it will not protect for specific components. Keep a spare one with you when you are out, the fuse do not blow often but it seem to happen when you are out in middle of nowhere. :)
@@maximumparts awesome, thank you! I'll be ordering some of the resettable fuses I've seen online, so having a spare shouldn't be an issue. I have a 5-pin single phase regulator, would I be right in thinking that the additional wire is a signal wire? I believe I can run it without the 5th wire connected, but would I be right in thinking it should be wired to the ACC output on the ignition switch? :)
Don't know about the 5 wires, there's so many of them that it is hard to keep track of the wiring. Send us an email, there's a contact form on our website and we will check. It could be 2 things at least, 3 wires for the AC and 2 for the DC output or 2 wires for AC and 3 for the DC. It all depend on the regulator itself.
I've checked every part and works. I believe I have an AC cdi btw. So the problem is I turn the key to the on and it burns my fuse. I put a 20amp fuse and on on it turns red but doant burn then I try to engage motor and it burns out but it dosn't even sound like it engages anything in those seconds...help
First you should keep the proper fuse there. If you put a bigger one like you did, you will burn the wires or components. The fuse is there for a reason, burn when something goes wrong, like you have now. You probably have a short somewhere and this is why the fuse burn. Take a multimeter and test things like I do in the video and you will find the problem.
Was wondering if you know where to order the 150cc engines online?
The engine in the video is this one: gokart.maximum.parts/engine-internal-reverse-gy6-150.html
Did you cut that buggy in 1/2 and remove some from the center and make a SINGLE seater?
No they came that way..i have 2 single seater 150cc buggies
How do I wire it if it’s a AC cdi
Is there a link from where you got your wiring harness?
He literally made the harness. Are you dumb
Anyone know ??
Hey guys. huge fan of your gy6 tutorials on you tube! I recently bought a beat up kart off of Craigslist as a a fixer up project. before this i had 0 experience or knowledge working on a project like this. It’s been a lot of learning along the way and already hit frustrations. Mostly with trying to figure out what kind of machine i have. it looks Like the previous owner scrubbed the vin numbers off so i have no idea about model numbers and all that. anyways the wiring for this kart was shot and bridel wires breaking so i decided to scrap it all and start from scratch. i have concluded that i have an ac cdi gy6 which not that big of a difference from the dc cdi. But my engine has what i think is called a diverter relay. Not sure how to work that into my wiring diagram?
This is why it's only a Basic Wiring, it is meant to help people start the machine first. Soon the machine is running, the rest can be added after. Specially in your case with a beat up machine.
Yes I have a yerf dog 150cc go-cart and need a wiring diagram to put a harness and everything new on it please help
You can follow this video and your Yerfdog will work. Double check which CDI you have on your machine first, AC or DC. The one I use in the video is DC. For the parts, you can check gokart.maximum.parts/ If you have any questions on the parts send us an email on the contact form and we will answer you.
Great video thanks
Do I connect directly to the battery
Do I connect directly to the battery to charge
@MARY LOU AVILA take the red wire out of the regulator and plug it on the ignition switch wire and one side of the fuse. The other side of the fuse goes to the battery.
Do you sale the exactly same full wire harness with components?? I have the set exac same engine with no harness
We don't sell the wiring harness. Multiple machine use the same basic wiring harness but all of them are slightly different. We would have to carry multiple wiring harness. If you are looking to make your own, we do have the connectors. This is the link: gokart.maximum.parts/catalogsearch/result/?q=connector
I have the same engine you have I have no diagram or any type of wires it's just plain... I purchased a wiring harness on eBay and it keeps getting burn out like it got to a point where it was melting the wires so I just gave up on the project but I look at your video and it gave me hope lol ...
My harness has 3 wires to the Ign Sw, Black, Green and a Yellow/Green. 2 more Black and Yellow in the harness to the kill switch. It goes into the frame rail for a few feet on my DUNE 150. Buggy cranks and runs if I cross the Start Solenoid lugs. But I have nothing coming out of the solenoid to the starter switch. Which wire is the Hot at the switch? None are red. 1 is Yellow/Red but goes to Yellow Green at a block plug. I bypassed the brake sw and it has 12v running threw. Fuse is good, current on both sides. Which way does the current flow threw the stock wiring? Green wire from CDI feeds switch?(IDTS) Yellow/Green(Yellow/Red at solenoid) wire feeds switch and current goes back to CDI threw Green? IDK, and the diagram doesn't specify. I got a new Rectifier and it didn't help. New CDI didn't help either. I have continuity threw Yellow/Green wires from the block plug at the engine to the Ign Sw.
2 small wires come out of he Starter solenoid, Yellow/Red that does a loop to the Brake switch and the resistor, then back to the BIG POST with the 12v lead from the battery. There is also a Green/Yellow wire that goes to a block connector and becomes Yellow/Green and that goes up to the Ignition Switch. This wire has no power.
My 1502r the headlights turn on when I push the brake pedal in. Any idea why.
Your headlights are connected to the brake switch. When you push the brake, there's a pressure switch that close the connection and your brake light turn on. The only way your headlight turn on when you brake, it's because the power is coming from the brake switch. The headlight should be connected to the accessories of the ignition switch.
Just wondering how important is the resistor because the only company that has it for sale is the one in your video I can't find it anywhere else
The resistor is really important, it regulate the power going thru the enricher on the carburetor.
The way I understand it. On the cdi. It’s an AC when it has a kill wire. Dc would just turn off with the ignition so the red and black wire from the stator powers the cdi. I’m confused on what is my understanding.
On the Chinese one do you know the wiring to the relay 30 85 86 76? and yes this helps alot. Thanks.
I assume you talk about the square relay. This is a common relay use in many automotive application. 85 - 86 is the voltage in that will engage the relay. 30 - 87 will connect together when when voltage is apply to 85 - 86. if you need more help, send me an email thru the contact us form on my website and I will send you a picture. I assume your relay is all fade out and you can't see what goes where.
@@maximumparts How do I send a pic? Web page is??
Good video have issues my ignition has 5 wires how do I go about this method I have juice Evan when I turn switch off from red wire
The red wire goes to the battery, this is why you always have power. As for the 5 wires switch, I plan on making a video only on ignition switch and show the difference between them.
Correct but when you turn switch off you had no power on red or white I still have power on red
@@traviswelch7876 yea if you ran a power wire from starter relay to ignition switch it would always have power because that's directly from the positive side of battery. so im wandering how he didn't have power as well
@@DWM_RL @Travis Welch Sorry for the delay, I never saw your answer. RUclips only notify me when you put the full @myname. The red bring the power form the battery, always, no matter what you do with the switch. When the switch is at the off position, the red wire still have power but do not supply it to any other wires on the switch. The white wire have power when the switch is at accessories and the start position. The Green wire from the switch only have power when the switch is at the start position. The reason is because you only want power to the solenoid when you are at the start position otherwise the starter would keep spinning even when the engine is running. Not too good for the starter, you would burn it. The CDI is connected to the white because you want power at 2 step (accessories and start position), when you are at the start position, otherwise your CDI would not have power at the start position and your engine would not start. The Red is the source of power and it is use to redirect the power when you turn the key. If the Red didn't always have power, it would not matter where you turn the key, you would never have power no where.
@@DWM_RL Ok, I re read what you say and I think I figure out what confuse you. I think you talk about the 2 bolts on the top. When the starter relay engage, the big wire connect the 2 bolts together. When you remove it from the start position, you disconnect one side of it, the side where the starter is but the other bolts still have power because it is connect directly to the battery. In other words, I create a Y to split the voltage between the starter relay and also the ignition switch. This side always have power this is why I use it. I could also connect the big wire to the battery and start another one from the battery and it would give me the exact same result.
my gy6 doesnt provide to much spark what is the problem and when i connect the regulator my engine is idle and then dies can you help me?
It can be many things. Change the spark plug first. As for the regulator, you might have a short somewhere and when you plug it, the short happen. Check the wiring like I show in the video and make sure everything is connected properly. Check your grounds, this is a common problem. If any ground is bad, you will have all kind of problem, including weak spark if the ignition coil is not grounded properly.
@@maximumparts it's 2 grounds so it's much better to ground them together on the engine?
Do you sell a complete harness ? Mine is all chopped up and spliced together
Sorry, I don't. The problem is every wiring harness are different. So any wiring harness you will buy will need to be modify unless it is specific for your machine. The only thing I have is the wire and connectors to help you rebuild. This is the link for the wire: gokart.maximum.parts/catalogsearch/result/?q=wire and this is the link for the connectors: gokart.maximum.parts/catalogsearch/result/?q=connector
Can I use this for kymco 70cc atv
The principal is always the same. The connections might change. Like when I do the ignition switch, I go with deduction. Power in, accessories and start position. For the CDI, you need power, signal from the engine and send the signal to the ignition coil. If you eliminate each wire one by one and draw the electrical plan, it will make sense to you at the end. As for your answer on the Kymco 70cc ATV, I can't answer because I don't see the electrical plan or do not have the machine in front of me to make sense of the wiring.
Nice
This is a really good video. I wish I could use it but mine is an A/C CDI. I’m not sure how to use your video or convert since mine is A/C powered. I actually watched last year but failed over and over. So I’m back at it again. I can’t be this dumb! Lol 😂.
Thanks. I will not give you the full answer but will give you the step to get it done. I assume you have all the same parts other than the CDI.
1. Find the diagram for a GY6 150 AC CDI and also the GY6 150 DC CDI. I think there's 1 or 2 differences.
2. Identify the wiring difference between the 2 CDI. The wires that are at the same place, put them first. That will eliminate some wires and make it easier to continue.
3. In the video, I say I have a Red-Black wire from the stator but we don't use it. In your case you want to use it. This is the AC wire that will plug to the CDI. Chech the AC CDI plan again and plug that wire to the right place.
4. In the video I have a wire coming from the Ignition Switch Accessories going to the +12 volts of the CDI. In your case, you DO NOT plug this wire. If you do, it will short the electrical and cause damage.
This is a add on if you want to understand a bit more. On a DC CDI, when you turn the key to accessories it supply +12 volts to the CDI and charge the Capacitor inside to get the spark ready. On an AC CDI, as you turn the key, the stator will supply voltage and charge the Capacitor and same thing again, will get the spark ready. An AC CDI is usually a little bit harder to start when the temperature outside is cold. An AC CDI have a rev limiter. A DC CDI will start easier as it's charge directly from the 12 voltds from the battery. A DC CDI do not have a rev limiter. Well the one I sell for sure.
Post the info when you will get it to start as it might help other people down the road that will re read this comment.
As for the dumb part, I don't think you are, I think you never did it before and you are a little bit worry.
Go slow and take your time, 1 wire at the time and you will get it.
If you need more info, let me know.
Genius!
plan for dc or ac cdi and instalation
Kudos
Question, a guy gave me a chinese go kart similar to this, and i changed the fluids and new battery, when i use the key accesories/honk used to work but starter would not engage when key is fully turnt (starter works, i pulled it out and tested it myself) . After a few tries, now the accesories/honk wont even work. What could it be ?
Sound like the ignition switch is bad. If there's accessories on the machine like high power lights, it will damage your switch. It can also be the starter relay. But now you say nothing is working anymore, it is unlikely.
@@maximumparts Thanks so much, i’ll keep you updated because i also fount a bad fuze, hopefully that was the reason accesories went bad
Okay, i fixed the fuse , starter cranked in the beginning but i stopped and redid it again, and the cables that comes from the motor was smoking, and now starter isnt engaging. Any tips ?
Change the cable. You have a restriction / bad connection and this is why the cable smoke. You try to push more power to a cable that can't support it and it transform in heat instead. Soon you change the cable for the proper one it will work, unless you damaged something else.
How do I connect the cable to charge the battery
red cable to positive, black to negative
Is there a way I can contact you to ask a few questions? I am stuck with wiring my go kart and you will most likely have the answer.
This is the link for our store contact form, gokart.maximum.parts/contacts/
Pin number tree 👍👍🐴
Thanks for sharing
LOL. Hope it work for you, knock on wood.
@@maximumparts thanks. I will try to check my wires in the morning. I been having to jump the solenoid to start it. It's a yerf dog 150 gy6
Try to follow the video, if you have any questions, send us an email on the contact form on our website. We will do our best to get your machine working. The troubleshooting video will come later. We've been busy shipping parts and didn't have time to do more videos.
@@maximumparts 👍
I'm keeping up with this now as well I just got one and have replaced everything and it only sparks when I let off key
I noticed you are not grounding both ground pins on the cdi? I can't get my gy6 150 to spark but all components are testing good. 🤷♂️ May have to use this vid to start from scratch.
I didn't because it depend on which CDI you have. You can check with your multimeter for continuity test between the 2 connectors. If you have continuity, mean they are the same and you can plug both.
I did have this problem before. I switched the spark plug and everything work. It might just be a bad spark plug.
If not, you can check the video on the CDI, ruclips.net/video/kFsyleMQXMc/видео.html I explain the wires in details. You will also be able to confirm if you have a DC or AC CDI.
@@maximumparts I definitely have a DC cdi because power comes from the battery and not the stator. When the key is on I am getting 12v to the power pin and I have continuity in the stator pickup coil wire and the ignition coil wire. I've tried 3 cdi boxes now and none of them are producing spark. I've tried 2 ignition coils and nothing. I've tried 4 spark plugs and nothing. I also have a new battery at full charge.
I watched your cdi video. It is awesome. Never seen anyone test continuity on the pickup coil by passing the protrusion of the flywheel over the sensor. Very cool!
I could not test for kill switch since mine does not have a kill switch wire at the cdi. The power wire to the cdi does come from a power terminal where accessories are served as well as ground. I suppose kill switch is part of that ground terminal somewhere? I don't even know if I have a kill switch. I do see a "kill switch plug" under the dash. It is just a 2 pin plug wire connecting a green/black and a green wire. 🤷♂️
@John Prater Seem like the last thing would be a bad ground. If you have a bad ground, you will have power going thru and will work on continuity test BUT will not deliver the full 12 volts. I got that problem also on one of my machine. Just check your ground and you can even put a temporary wire for each ground.
As for the test I do, I try to find simple test anyone would be able to do without too much knowledge. One thing I never try is the output of the CDI going to the ignition coil, you should also have power coming out to supply the ignition coil. I don't know if a multimeter will pick that up. I know an oscilloscope would.
The kill switch is connect directly on the wire going in the CDI from the Pick up coil. The CDI respond to the pulse. By grounding it, the CDI receive nothing and stop the power coming out to the ignition coil.
Check your grounds, that would be the last thing. I would be surprise ALL the parts you have are bad.
@@maximumparts It is indeed the kill switch! For some reason the ground from the ignition coil went into a connection on the ignition which is wired to a kill switch plug. A kind of 2 pin pig tail. I cut the ignition coil ground wire and connected it directly to the engine ground and it fired right up! I can't tell where or how it is bad with it's factory setup... I'd have to open up about 5' of loom from underneath the body and inspect.
I suspected this was the issue but couldn't figure out how. Your videos helped where others didn't. Subbed!
Why is the red black wire from the stator not in use?
It is only use if you have a AC CDI.
My 150cc got kart 2 wires to the starter solenoid are hot. I’ve already replaced the solenoid 3 times so I don’t think that’s it. The 2 wires stay hot the whole time it’s running. It will start and run but I have to hit start it because when I turn the key it only clicks. So after a hot start I’m golden I just unplug the starter solenoid and I’m good and wires aren’t hot anymore.
This is a hard one to answer. Check with a multimeter. Can be a short somewhere, a bad ignition switch.
@@maximumparts ok so with it running and unplug the solenoid both the wires shouldn’t have anything?
You should only have power to the solenoid when the ignition switch is at the start position. If you are on the first click / accessories, you should not have power to the solenoid. The solenoid is only use to trigger the starter. Soon the engine is started, you don't need the starter to spin anymore.
@@maximumparts ok I will check those wires. I do just have a click in the back when I turn the key. I do also know that both the plug wires get hot. After I unplug it it’s fine
Good instructional video!!! Would like to see a AC CDI Version also. Thanks for sharing.
Thanks, took note for the AC CDI.
My mans over here doing the lords work! Man what’s ya cash app so I can buy ya a beer! I just rewired the whole Trailmaster 150 xrx with ya video. Thanks a ton man.
Happy it help. What about next time you buy your parts from my store, gokart.maximum.parts/ I did the video as I received a lots of emails about the wiring. It was easier to make the video than answer all emails. Now, I can send the link when people need help. :)
If my resister is bad can it keep it from firing
@Ronald Lawson No. The resistor is only use for the enricher. When the engine will run it will run rich and stall when you push the gas pedal.
where can i order a wiring harness for this engine family y9tjpx
@Ricky Vasquez all wiring harness are different. You would have to find the exact wiring harness for your machine otherwise you will have to make it work. At that point, it would be easier to make one from scratch.
Where can I get the ignition switch
gokart.maximum.parts/ignition-start-switch-3-wires.html
Okay so what if the yellow wire to the regulator is burning hot ?
@markymonjaras You have a short somewhere or you are using more power than your machine can produce. This is the 2 main reasons. A short will touch at least 2 wires that are not suppose to touch and will increase the power and this is why the wires come hot. If you installed bigger lights, the same problem will happen, you are asking for more power than the machine can produce and the wires will come hot again. Eventually a part will give up cause of the heat.
Need help ....Video is great I am rewiring entire buggy. I started and followed you. Up in till it turns over . Then my problem I think I have a performance CD i with a small red light it has wires coming out of it not just plugs attached to it. Plugs are on the end of the approx. 6 inch wire. Now I followed video but when I went to try a start up to check fire I got this. When I turn key on the little light on the CD I comes on which I think it should only flash as the pick up coil passes it’s mark and no fire at all . Just can’t figure it . Any help please ?
Sorry can't really help. I don't know which CDI you are talking about and even if you show me some pictures, I will not know the wiring. Did you check with the seller to get the info on the wiring? Also, is it a DC or AC CDI? This is what you need to know to get it right. One thing you could do is to use the original CDI first and make it work and after troubleshoot your new CDI and make it work.
@@maximumparts it is a DC and same one only a new one I bought because the old one had no plug ins they had the old one all cut up but I did have it running. It's a blue cdi for 50 to 250 cc
@@maximumparts I will keep plugging away with it but any feed back be appreciated. Just I stripped the old harness they had all patched up and taped and trying to do a complete new one
Don't know nothing about this CDI. Maybe the CDI is bad, this is why you should get the basic one first and when you know it work go with the blue one.
Sorry, don't know nothing about this CDI. Check with the company you bought it from, they should have the info on what they sell.
What is the black red wire?
It's the AC Power if you have an AC CDI.
Sir what is the wiring diagram of gy6 engine
This is the link to download the electrical plan in PDF: info-gokart.maximum.parts/how-to/go-kart-150-wiring-harness-from-scratch/
It will work with a GY6 150 as long as you have a DC CDI.
The PDF plan is clickable, mean, if you click on a part, it will bring you to our website, and you will be able to get more info.
I didn't use the original electrical plan because some have mistakes in it. I decided to do my own. The thumbnail you see for the video is the actual plan I did.
What does it mean when my go kart runs for about 10mins and the starter solenoid is super hot
@Martyimgay Well it should not be hot. Maybe it's because the solenoid is still engage and the starter is at the same time. It you check the white plug on the solenoid. Soon your machine is started, you should not have power to this plug anymore. If you still see power coming in with a multimeter, it mean something is wrong.
@@maximumparts my solenoid only has 2 wires but what your saying is one wire shouldn’t have power at all after unit is running. Also the starter wouldn’t have power either
@@Martyimgay The solenoid have 1 plug with 2 connectors and 2 botls on the top that send power to the starter. The first thing you have to check is the white plug, when your machine is running, put a multimeter on both wires and you should not have voltage. The next thing would be to check the starter itself, you have one red wire coming on top of the starter, this is the +12 volts and the case of the starter is ground.
@@maximumparts ok I had to u plug my solenoid because it’s buzzing when cart is running. I checked it and it has power on 1 side with it running and little power on the opposite side. Unplugging it 1 prong has power and the other dont
Can these fit a 110 cc go kart ?
The logic yes but the exact wiring no. Every engine will use their own parts. In your case, the CDI should be different and some other parts. If you follow the logic of the video, you should be able to make it work.
are all the talon 150 dc i followed this plan still no spark and all the parts are new
@Bj Loomis Not all Carter Talon 150 are DC CDI, some came with a AC CDI. But if you did the entire wiring like I do in the video, it will become a DC CDI. Which CDI you bought, AC or DC?
i thought it was dc but it isn't it is a ac
can i wire it ac if i want to
Yes you can. BY MEMORY, the only wire that change is the power, you will need to use the red-black coming from the stator. Double check before you dod anything.
Where can I find that resistor
This is the link for the resistor in the video: gokart.maximum.parts/resistor-comp-10w-10-ohms.html
I need all the parts from the starter the battery I don't need to start I got one but I need a battery for the wiring for the firing I want to do I'm put all new parts on it is there a way I can get a price on all of them even count the battery
I did everything you did and can’t get spark
Where can I get the hardness
To find the exact wiring harness you need for a specific machine is hard. They are all different. Mean, unless you buy the exact wiring harness you need, you will need to adapt it. If you are looking to make your own, we do have all connectors and wires. This is the connectors, gokart.maximum.parts/parts-by-type/electrical/connector.html If you need the wires, this is the link, gokart.maximum.parts/catalogsearch/result/?q=wire
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@ joey mtnjunkie puig Thanks, I am trying to get more videos done. Good thing you subscribe, you might like what's coming soon.
Hi, how is the best way to contact you for help and questions?
On the website, gokart.maximum.parts/contacts/
Maximum Parts I’m in Australia, wondering if you can send me a link to a key ignition with accessories and start position. I can only find one with 4 wires not 3? Thanks
@@quadzagamingtv3066 This is the link for the 3 wires ignition switch, gokart.maximum.parts/ignition-start-switch-3-wires.html
Maximum Parts I need a link to a key ignition that will work on eBay.com.au as I can get parts from America during Covid or is really expensive. If you could send me a link to one suitable and what colours to use that would be great
I have no idea. I never buy from eBay no matter which country. I also received a lots of email from people buying things on eBay and some other similar company and they have problem. The seller don't answer most of the time. Even if I find a link on eBay, I would not be able to confirm is the switch will work and if it will power your machine. All switch are different with different amps rating. Send me an email and we will check for the shipping cost.
Is the cdi an ac or DC cdi?
Someone said if it’s a big box it’s dc and if it’s a small box it’s ac
No full wire up as of yet, be awesome if someone did one using a replacement harness full install
hi i spent the last 2 weeks watching your video and learning how to wire my buggy 2 days ago i started to disassemble everything yesterday i got to the point where the engine started to turn over from the ignition with some difficulty cause the solenoid died on me and yesterday i finished wiring everything and when i finished i started to crank the engine over and jt woildnt start when i took out the spark plug i was to find out that there is no spark,i did everything the same way you did in your video is there any way you could tell me what could be wrong i checked the stator solenoid and my ignition coul but they both work can you try think of what could of went wrong if the top of your head please
I assume you did the wiring exactly like I did. If this is true, that mean you have an AC CDI. that would explain why the machine is not starting. The red-black wire coming from the stator, the one I say it's not in use, this is the wire that usually would go to the AC CDI. Was that wire connected to something?
it was connected to the top right beofrr
and also could you tell me what a trigger ground is and 12v ac power
It's hard to answer that one, don't know what you mean, top right. Go on the website and send us an email, gokart.maximum.parts/contacts/
Maximum Parts i sent a message can ylu look at it and respond afap please
I have replaced the entire electrical system, and I still cannot get a spark
Link to harness ?
The purpose of the video is to help people make their own wiring harness. As every machine use similar harness but not the same, if you plug a different harness, it might not work the way you want. You will have to change the wiring anyway.
If you want to make your own harness like in the video this is the link for the connectors: gokart.maximum.parts/parts-by-type/electrical/connector.html
If you need the wires, this is the link:
gokart.maximum.parts/catalogsearch/result/?q=wire+16+gauge