I recently purchase a 125 Kasea Adventure Buggy, I think its a 2000, its yellow anyway. It hadn't run in some time and both the battery an ignition switch were toast. I replaced both and got it sort of running, what I mean by sort of:
The engine will start but will not run unless the ingition switch is kept cranked into the start position. This was confirmed by disconnecting the starter holding the switch over and kick starting it. With the ignition in the run position only there is no spark.
I was carefull when I took the wires off of the old switch to put them back on the new switch in the same locations.
Battery hot is white, ignition is green and the starter had two (2) black wires crimped into one terminal.
I was suspicious of the two wires on the starter circuit and put them into seperate terminals but putting the the non-starter one onto the ignition (with the green wire) didn't solve to problem either. I currently have the white to hot, the green to ignition and both blacks to start but the buggy still will die as soon as the key is released. I suspect something is bad (cdi?) but am at a loss about where to look next?
Definately not the cdi. I would look into the starter switch, and especially into the starter solenoid its self... could you jump start it and it stay running from the poles on the solenoid? Can you eliminate the switch entirely by combining the hot and the ignition wire, and jumping it to ground to see if it will stay running? try these out and let us know. To me, it sounds as if you have a bad switch, or solenoid... I do think you should start to eliminate parts first... Try eliminating the ignition switch entirely, and see how the engine starts or what happens... If nothing works after removing the switch from the equation, then you can summize that the ignition is not the prblem, that it is further into the starter circuit... Trace the wires to their poles on the ignition coil, the solenoid and the starter, check for obvious signs of damge/over heating and such...
If it starts, and runs, then it's not the CDI. The wiring is messed up somewhere. Trace the wires back, draw them out and compare them to a wiring diagram. Most of them are the same or pretty close...
If you have a meter you'll be able to trace the wires a lot easier.
renegade2 wrote:
I was carefull when I took the wires off of the old switch to put them back on the new switch in the same locations.
Battery hot is white, ignition is green and the starter had two (2) black wires crimped into one terminal.
I'm not certain the two wires would go to the starter. I would think they would go to a "common" terminal on the switch. Are you sure you replaced it with the same switch?
Obvious stuff at times, but it doesn't hurt to check.
Let us know how you make out.
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TeamHog _________________ Chris Dierkens
'04 Yerf-Dog 3206 10g Rollers, 1500# Spring, Reverse, SuperTrapp, Uni
'04 KPX Xterro: pumper carb, oil cooling, 10g rollers, Junkies pipe, Uni
'05 Blade 150 DX: 4 Valve head, 10g rollers, East Side pipe, Uni
www.northeastbuggy.com
Since it runs in the start position and not in the run position the first thing I would try, just for kicks, is reversing the position of teh green and black wires.
Actually before you do that get a volt meter or test light and make sure you have the right hot lead connected to the batt terminal of the switch. _________________ 05 Jehm Adventure Buggy 250cc, Torque Spring, 22.5gr Rollers, Modified Roll Cage, K&N, 21x7x10 & 22x11x10 Trac Star Radials, Vapor, Body Panels, 40T Spkt
&
2003 Jehm Blazer 125cc, Vapor
10 gram rollers, 20x10x8 Razr's,
34 tooth sprocket, 9pk cooler
Verified that the white is battery hot. I used a multimeter from the wire to ground for this.
Verified the problem is not the switch: I hot wired it by holding the battery (white) and ignition (green) together and bringing both black wires into contact with these. The engine will start but dies as soon as the starter is taken away (only one black wire spins the starter, I have no idea what the other one does, I have also tried leaving it tied into the bundle and just removing the actual starter lead, the engine dies).
I have already thought of the green wire possible being the starter lead and ignition being required for it to spin as someone suggested above. but the one black wire hooked to battery hot spins the starter (motor will not start). The green to battery will not spin the starter.
I pulled the cover off of the metal box that contains the cdi and the starter relay (recifier too) and the fuses in there are good.
I may try to take some pictures and put them up, though I have no clue what good they will do.
If things are acting like you expect them, then the best bet is going to be to wring out the wires and verify/confirm where they are going. Make a diagram of the electrical system and then evaluate as to wether or not it makes sense.
Here's the wiring diagram of a Yerf-Dog. If it helps, great. If it doesn't oh well.
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