Need help from an electrical guru on a go-kart

[jpcjguy]

Hi all,

So I am putting back together a go-kart/buggy for the kids that I picked up recently. I can get it to start by jumping the solenoid but not with the key. The ignition switch is good and when in the starting position - I have 12v going to the starter solenoid (brand new and is good).
It appears that there is no "ground" on the other side of the starter solenoid. I traced the wire and it goes to a standard relay. I tested the relay and it is good. I hear the click. I don't know what the function of that relay is though.
Here is the supposed circuit diagram from the kandi (manufacturer) website:

Is this a "ground" based setup? Could it be that I am not supplying 12v to the starter solenoid with the key in position 3 but actually providing the ground to complete the circuit? In the pic, on the left side there is a cut off switch which appears coming from a relay (labeled "engine start stuff") - I don't see a kill switch (cut-out switch in the diagram) on the buggy. I wonder if the previous owner messed with something?
Electrical is not my strong suit so any help would be great. I am having a tough time following this diagram and if someone could walk me through it, that would be awesome!

Thanks,
Joe

 

[gungatim]

is this one of those 150cc fwd/rvs cvt buggies? if so I just finished rewiring one so maybe I can help

 

[jpcjguy]

is this one of those 150cc fwd/rvs cvt buggies? if so I just finished rewiring one so maybe I can help

Yes it is. It is the standard 150cc GY6 buggy with CVT and F/N/R. Here is a pic:

 

[gungatim]

OK, mine is silver but should be the same.

the solenoid is hot all the time. you ground the G/Y wire through the brake switch then the push button. the other side Y/r wire is hot through the fuse and rectifier.

I re-wired mine to take the brake switch out of the equation and used an regular boat key switch for starting and separate kill switch for the CDI.

 

[MikeF2316]

If only cars were this simple.

Ignoring everything not needed to make the starter turn:
The wire that connects from 1 on the ignition switch to the starter motor, battery, rectifier and onward, consider that your ground.

The other side of the starter motor is connected to the battery hot through the switch contacts of the relay.

In the start position, 3 is connected to 1 (grounded). This grounds one side of the winding of the relay. The other side of the winding is connected to the hot side of the battery through the "fuse patch"

When current flows through the winding, the relay clicks. Just because it clicks doesn't mean it's doing what it's supposed to - connecting the other 2 terminals together.

 

[jpcjguy]

If only cars were this simple.

Ignoring everything not needed to make the starter turn:
The wire that connects from 1 on the ignition switch to the starter motor, battery, rectifier and onward, consider that your ground.

The other side of the starter motor is connected to the battery hot through the switch contacts of the relay.

In the start position, 3 is connected to 1 (grounded). This grounds one side of the winding of the relay. The other side of the winding is connected to the hot side of the battery through the "fuse patch"

When current flows through the winding, the relay clicks. Just because it clicks doesn't mean it's doing what it's supposed to - connecting the other 2 terminals together.

Thanks for info. So I had a brand new solenoid that I assumed was good. I was questioning my brake pressure switch and horn connection so I jumped those connections (bypassed the brake switch and horn). Lo and behold I heard the solenoid click! But nothing after that....huh?? In the start position and the solenoid clicking I had no voltage on the other side of the terminal. So I pulled the solenoid and tested it by itself. Yup - I can make it click all day long but the main terminal (battery side) never connects to the other side (starter motor). Ordered another one tonight.

 

[gungatim]

yeah sorry I didn't get a chance to call last night, we had big storms here...

but you got the gist. even if it clicks (mine did) doesn't mean it's making contact.

I sourced new solenoids on amazon (they are pretty much all the same/universal).

$6 or so for a new one, but a good deal is the coil, solenoid, plug, and CDI all in 1 for like $15...I always order at least one extra when I buy that GY6 stuff since quality can be hit or miss and there is always another one begging to be fixed...

Have fun, those karts can be a blast. just make sure the rear tires are mounted correctly, mine were mounted backwards with the tread the wrong way, LOL!

 

[jpcjguy]

yeah sorry I didn't get a chance to call last night, we had big storms here...

but you got the gist. even if it clicks (mine did) doesn't mean it's making contact.

I sourced new solenoids on amazon (they are pretty much all the same/universal).

$6 or so for a new one, but a good deal is the coil, solenoid, plug, and CDI all in 1 for like $15...I always order at least one extra when I buy that GY6 stuff since quality can be hit or miss and there is always another one begging to be fixed...

Have fun, those karts can be a blast. just make sure the rear tires are mounted correctly, mine were mounted backwards with the tread the wrong way, LOL!

No problem. Hopefully it is just the solenoid. Otherwise I will be reaching out again.
I will keep you posted.