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Disconnect the solenoid, you should have a white plug similar to the one in my video. On the wiring harness side, check if you have 12 VDC when you push the button. If you have nothing, it mean the problem if before the solenoid. You might be right on the security feature. If you have 12 volts, you solenoid is dead. When you short the 2 bolts on top, you bypass the solenoid and the security if you have one.

@maximumparts yes, on another video someone said that this harness has a brake lever sensor that prevents the bike from starting unless the brake is activated and that you can just tape the two spade connectors together to bypass and start but I did this and still not starting with the push button, the only thing connector that I am not sure whether I need or not is a little two pin white connector near the brake lever sensor wires, it has one yellow wire with an orange stripe and one solid green wire, could this maybe be a clutch connector and therefore I have to bypass not only the brake lever sensors but also this one as well? I thought this little connector was for brake lights but maybe that's where the safety feature it gets it's brake signal from (activated brake light and not an actual sensor at the brake lever) but I do not want to twist these wires together unless I am certain what they are for and sadly I cannot find any harnesses online with the same color wires as mine aha, quite a rollercoaster this is! thanks a bunch for your response!

Follow the wires from the start button, one should go to the ignition switch and one will end up in the back to the solenoid. The wire going to the solenoid may have the security brake, follow the wire to see where it goes and narrow it down. If it a switch, you will see it and be able to bypass it if you want. Just make sure you have the right wires. As for connecting wires without knowing you are 100% right, you should not, if you guess wrong, you will create other problems. Fixing wiring is not easy so take you time. Also, you should subscribe to my channel, I have more things coming that might help you. :)

Those are the wires from the stator that goes into the regulator.

This is the link to buy the wiring harness: gokart.maximum.parts/basic-wiring-harness-gy6-150.html

Welcome 😊

As long as they are coming from the stator it will work. Like you see, some came with 2 yellow wires and some came with 1 white and 1 yellow. Same thing.

@@maximumparts okay awesome, so they're both accessories for lights or something so it won't brake anything? awesome thank you so much bro

@maximumparts I asked another guy earlier and he told me to splice the yellow and white from the harness side together and then connect to the one yellow on the engine side and then ground the other yellow to chassis but this explanation is way easier!

@@maximumparts so just to clarify, it doesn't matter which yellow wire from the engine I plug into the white wire on the harness? and what would happen if I left those unplugged and only had the white/blue and red/black and green wires connected together?

They are not. They are AC power coming from the stator and going into the regulator to change it to DC 12 volts for your machine.

I have a few 5-wire ignition switches; all are different, so it's hard to give you the information. The best way would be for you to buy the 3 wires ignition switch I use in the video and the connector. These are the links: Ignition switch: gokart.maximum.parts/ignition-start-switch-3-wires.html Connector: gokart.maximum.parts/connector-3-way-6-3mm.html At that point, you will be able to follow the video.

@@maximumparts thanks for the info

Thank you for your comment; you are right; this is not an easy task. We have a plug-and-play wiring harness for sale if you want to make it easier. This is the link: gokart.maximum.parts/basic-wiring-harness-gy6-150.html. We also made a video on how to install it: th-cam.com/video/dXP3SFopKVY/w-d-xo.html. I repeat the process differently because not everyone will see and understand things the same way. You might have a different result if you do not have the exact components we use in the video. If one wire is plugged incorrectly, it will not work. Making it a 5 minutes video would be too fast; even with this video, I would pause it. The information in the video is meant to help people understand what they are doing and test as they are doing it to make sure the step was done correctly.

If you hear nothing when you turn the key, & you know your battery is charged, check the fuse right beside the starter solenoid. Mine is 15a. It's probably under a plastic cover beside the air filter & carburetor.

Basically, it is the same, so yes, it will work. In my case, I used a resistor that the case of the resistor is grounded; this will become an issue if the case touches the ground, and I'm using it on the positive side. If you do have a resistor with the 2 leads coming off the top, it will work 100%.

100% True. This is why I made the attachment with the 2 bolts you see in the video. There's a lot of pressure, for sure !!!

@@maximumpartsYes I wish I would have made one of those before I took mine apart lol

I can't find an accurate electrical plan for this machine. Make it harder to re wire the machine. You will have to check every wires, what they do and make your own plan.

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.

Thanks! Come with a basic 10A fuse and start relay. There's no Flyback diode with this wiring harness.

It will depend on your configuration. This is the link for the variator: gokart.maximum.parts/koso-performance-variator-complete-gy6-150.html This is the link for the clutch: gokart.maximum.parts/performance-full-clutch-assembly-gy6-150.html

It's two plates with two bolts. That was in a pill of junk metal in the corner of the shop-nothing special. I did some before putting my two feet on top of the clutch, and if you slip, the clutch comes up. It is the same when you try to put the nut on top; if you cross-thread, you are out of luck again. It takes a little longer to tighten the two nuts slowly, but the result is always good.

Yeah I wanted to know what the piece was on top

The kill switch may have still been enabled

The chain is a 520. Don't remember the number of links ...

@@maximumparts ughhhh thank you??

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.

You should have 14.7 volts. It might be cause by the meter and not the machine. Putting a bigger battery won't help. You have to match the power consumption with the charging system and not the battery. If the charging system do not supply more than what you need, the battery will die slowly. This is why putting a bigger battery won't help, it will eventually drain the battery.

agreed but i need more amps than a electric kids car. i put a small optima battery with plenty of cca. and will power my 2 way radio and stereo and leds easily now plus while we are camping/karting ill have a small solar panel to trickle charge the kart batt just like i do with my radio eqt in the field..ill have a video soon on how i did it.@@maximumparts

ok rechecked it after replacing stator and gapping it to .015 and its dead on 14.7/8ish.. thanks@@maximumparts

This is the regulator we sell, it will work for what you need: gokart.maximum.parts/rectifier-regulator-3-phase-gy6-150.html If you need the connectors, we also sell them: gokart.maximum.parts/connectors-kit-for-3-phase-stator-regulator.html But that will depend on your connectors, they might be the same. CDI, you have 2 types, AC or DC, it will depend on your machine and wiring. If you want a video on all the basic wiring, you can check this one: th-cam.com/video/4U1ZulC22Zc/w-d-xo.html It should help you figure out what goes where.

yes thats the same as mine awesome will be ordering it.. also do you guys sell tops for a 4 seater buggy/kart by chance mine is a 2021 tiking 4 seater but same as the trailmaster and other 4 seaters..@mparts

You can go on our website and send us an email thru the contact us page. We will check with you for the other parts you need.

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.

Someone said if it’s a big box it’s dc and if it’s a small box it’s ac

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. :)

Can u help I’ll pay

I have same engine to

Which CDI do you have

Casoli moto it’s gold

Sorry, didn't see your comment until today. You know, not having spark can be the cause from multiple things. It would be long for me to enumerate all of them. If you follow the video, it should help.

@ramrebelmibrian4050 Good questions. If you want the safe side, check the wattage of the original lights and that will tell you the maximum wattage for the LED. If you need more, you could install a volt reader in the dash, this way you will see the voltage go down if you have too much power usage. If you separate both circuits it would work until the second battery will be dead. You keep the main battery for the machine and basic lighting and the second battery just for the add on lights. If you don't have enough power, you could use an 11 pole stator and regulator, gokart.maximum.parts/3-phase-rectifier-regulator-stator-11-poles-upgrade-kit.html This is if you have a 150 engine. I didn't do all testing yet but in my case, I was thinking about installing a volt reader on my machine and see the result.

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

I need some help