Quantcast
Jump to content


Looking for a Service Manual? Download Now! ×

Engine/ wiring harness help in my version of a "hybrid"

Strike37G

By Strike37G
in Other ATV Brands Forum

 Share

Recommended Posts

Strike37G Rookie

Strike37G

Posted
Posted

OK gang, first post so don't bust me up too bad. I am so out of my element here because I usually wrench Jeeps and an intermittent Charger.

I am taking a 250cc Zongshen engine and grafting it into a 2002 Yamaha Blaster. After modding mounts, carb, intake etc. I have ran into the problem of the engine harness to wiring harness. Both have 5 wires for the mag but the colors don't match. anyone have any experience with bridging the gap between the two? The first picture also has a 6 pin connector that I have no idea about. The second and third pictures are the loose engine wires and wiring harness with the connector. The whole project is sitting at about 95% and I'm ready to finish it. Any input would be greatly appreciated!

 

processed-48b385c8-675b-4130-84b1-0a4aa217d99b_crpV2vok.jpeg

processed-35a776de-4b33-4313-82c5-553831a0179e_Qj0kjFzG.jpeg

processed-27571ef7-ec11-48af-b457-d2a06ccfe2a9_j7vIvqCE.jpeg

  • Like 1
Link to comment
Share on other sites
Curtis Underwood Contributor

Curtis Underwood

Posted
Posted (edited)

Frst and foremost. You will need the wiring diagrams for 250cc Zongshen engine and the 2002 Yamaha Blaster. Wiring on the engine itself has:
1. The stator/altenator wires that will connect to the your regulator/rectifier on your ATV.

2. The engine may also have a neutral safety switch wires, oil pressure switch wires and or temperature switch wires. It depends on the engine to what wiring it has.
So unless you are good at identifying which wire does what. You will have to have the engine and ATV wiring diagrams. Then you if you are not real familar with electrical wiring, you should have someone that is do the connections.

Edited by Curtis Underwood
  • Like 1
Link to comment
Share on other sites
Curtis Underwood Contributor

Curtis Underwood

Posted
Posted

Does the engine have more than the 6 wires coming from it?
The engine stator usually has three wires that goes to the rectifier/regulator, one or two wires from the ignition sensor (depending on if the sensor used ground or not), and a ground wire.
The neutral switch is usually only one wire unless it has a shift indicator system, that gives which gear it is in then it might have a 6 wire connector.
Then on most engines you have a coil with two wires running back to the CDI.
Engines usually have either 9 wires to 13 wires coming from the engine going to the atv body.
Engines on early model machines have:
1. 2 coil wires one that leads from the coil to the ignition/stop switches and the other to the CDI.
2. 1 neutral safety wire that prevents the starter engaging unless the switch is closed.
3. 3 stator wires that got to the rectifier.
4. 1 ground wire from stator to body ground on atv.
5.  2 sensor wires that got to the CDI unit.

Engines on later model machines depends on the type electronic display if it has any certian wire:
1. 2 coil wires one that leads from the coil to the ignition/stop switches and the other to the CDI.
2. 1 neutral safety wire that prevents the starter engaging
3. 3 stator wires that got to the rectifier.
4. 1 ground wire from stator to body ground on atv.
5.  2 sensor wires that go to the CDI unit.
6.  6 wires from the shift switch (which includes neutral safety)
7.  1 wire from the oil pressure switch (optional)
8.  1 wire from the engine temperature switch (optional)

So you see how complex it can get. If you can not get a print that is color coded for your engine and one for you ATV wiring harness then you will need to trace each wire on the engine  and on the ATV harness to see what it goes to then hook it up to the corrosponding wire on the ATV.
There is no easy solution without the prints.

 

  • Like 1
Link to comment
Share on other sites
Strike37G Rookie

Strike37G

Posted
  • Author
Posted

yeah its 5 loose wires from the engine to a 5 wire connector on the harness. I will research more from the manufacturer of the engine and see what the 5 wires go to then back track. might have to skin the harness and trace with a MK1 eyeball and check continuity.

Link to comment
Share on other sites
  • 3 weeks later...
Strike37G Rookie

Strike37G

Posted
  • Author
Posted

Latest update. Got the Blaster to fire and run a few times then all of a sudden no spark. Changed CDI, rectifier, even the coil. Still no spark. Went through entire harness and beefed up the connection points. reinstalled no spark but I bumped the connector to the CDI got a slight "bump". Found out it was a bad connector. Swapped in a new one and voila! Starts, run and is good to go!

IMG_20220609_172036155_HDR[482].jpg

  • Like 2
Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

×
 Share
Go to topic listing

  • Similar Forum Topics

    • Mikey69
      How did you get into Quads?
      By Mikey69
      Heres my story. Kinda long. I guess I was a late bloomer when it comes to quads. I had never ridden a quad in my life. Rode Dirt Bikes as a kid growing up. Back in Oct of '06 I found a Mustang on craigslist. Took it for a test drive one morning before work. Fast car. 351 Cleveland. I had planned on meeting the guy again after work. For some strange reason thats still to this day beyond me, I stopped in Hillsboro MotoSports on the way home from work. I had 6 Grand on me. There was a left over '05 sitting by the front door. It was on sale for $4999. It was $5499 OTD. I didnt even look at anything else. I knew nothing about quads accept I thought it really looked coool and I had the money in my pocket to buy it. I was sitting on it when the salesman walked up and asked... "Can I help you?" Without hestitation I pulled 60 Ben Franklins outta my front pocket and said "I want this Quad. Load it up in my truck." It was just about dark by the time I drove away from the shop. BTW, I didnt bother to ask my ol lady if I could buy it. LOL. Anyway, I took it by the house and showed her. She was kinda stunned but not mad. We drove over to a friend of mines house and unloaded it. I took it to the field across the street from his house. HOLY CHIT!!!!! I was surprised by the power. I had it for about 2 weeks and took it to Sand Lake. I was there a few hours and rolled it on a banked turn at the top of the bowl right before you get to the one-ways. When it rolled, I flew off and landed on my belly. The quad came bouncing and landed on my back. For a month I couldnt even walk. I was scared of it. I considered trading it for a 250EX. Went back to the shop. The salesman said..."Dude!!! You dont want a 250EX!!! Trust me. Just get used to it" I still wasnt convinced. I put it on craigslist for $4000. Calls were coming in. I had a guy that wanted to come look at it that evening. I decided to take it for one last ride at Browns Camp before I sold it. I was still afraid of it. After about 5 minutes I started feeling comfortable on it again. I decided right then, I loved my Honda 450 and would learn how to ride it instead of selling it. That was late Nov of '06. Work was slow for a Painter in Oregon. My new job everyday? Going to Browns Camp and ridding my Quad. I bought my Girl Friend an '02 Blaster. I rode my 450 for 4-6 hours almost every single day for 3 months. And yes, I know my way around Browns Camp pretty well. LOL. In March I bought her an '06 TRX250EX (Thank God I didnt trade my 450 for one of those) LOL Since then, I have become totally addicted to quads. I love them. Couldnt imagine not owning at least one quad. Luckily I have two. My "07 was $6500 OTD in July of '07. Bought it for my Girlfriend. Traded in her 250 EX. A month later we broke up. So, I wound up with two Honda 450's.
       
    • HSTAR
      1997 Yamaha big bear 350 Shift shaft issue
      By HSTAR
      Hey I have a 1997 big bear 350 4x4
      I replaced the shifter shaft and the shift arm linkage and the rod when I installed them all I was unaware that you had to line the dot on the shifter shaft with the gap on the linkage arm gap put it all back  together and rode it I can't get it to shift in the right gears  I can move the shift cam by hand and goes in different gears but with the shifter shaft in it riding I can't put it in R or N 
      Anyone know how to line up the shifter shaft and the shift cam s
       
    • ResQ91
      1987 Yamaha Big Bear Electrical Troubleshoot
      By ResQ91
      Hi guys
      My 87 Bear 350 won't start and could use a hand.
      Turn key on and Oil light turns on and then slowly fades out. (I think this is key to this) No start, not even a tick.
      battery and connections good
      A Solenoid post jump turns it over
      Neutral Safety Switch wire attached and seems good
      It has not had a wire/switch on Rear Brake Pedal ever since I had it.
      Any thoughts on some other things to troubleshoot this??
    • jatho
      Best Engine Oil to use for Suzuki King Quad
      By jatho
      What is the best engine oil to use for the Suzuki King Quad - also any other tips and tricks I should know before doing an oil change on these bikes 
    • BruceG
      2005 Bruin 350cc Oil pumping into airbox
      By BruceG
      Hi guys. I have a problem where the quad will start and run well for about 5 minutes and then it dies. On inspection the airbox has oil in it (quite a lot). The oil is pumping through the cylinder head breather hose. This problem first happened suddenly. I have since done the top end including, piston, gaskets, rings and valves. I have also done the carb (not that I thought that this was the problem). The compression seems normal. The only thing that I can think of, is that I did not grind the valves well enough. Anyone experienced this? If so, how did you fix it? Any other thoughts?

COMMUNITY SECTIONS

ATV FORUMS

QUADCRAZY MEMBERSHIP

Be a part of best online community of ATV riders and join thousands of people who love ATVs! Share your ATV photos, videos, ATV rides, get help with your ATV and more. Not a member?

SIGN UP TODAY

ADVERTISE WITH US

FOLLOW US ON

  • Automotive Webmaster
×
×
  • Create New...