Andrew Baker

I can check the kill switch. If that is good I may get a new stator and rectifier. I have 2 rectifiers also. I just don't see them go bad too often. 

On 11/27/2019 at 6:21 AM, Frank Angerano said:

Wow great news, what was the problem? 

Do you have a neutral light when the key is on ? 

Did you jump the solenoid to verify that the starter is working? If not then do so, if it spins great then you can move on to the starter circuit. 
If the starter does not spin then your starter may be bad or at least the brushes inside it.
 

The starter relay circuit is pretty simple. Go to the usual suspect first.  The neutral safety switch! Your bike should have a red and a light green wire coming out of the engine on the left side where the shifter area is right above it.  There is a light green wire, take that wire and disconnect it from the wire going into the engine and put a jumper from a good ground to that green wire on the harness side and see if the starter works with the push button. 
If not then locate the stater circuit relay. It’s in the same area as the starter solenoid round aluminum relay in a black rubber boot holder. There should be four wires on the relay. Two black, one brown and one green. 
Jump the two blacks and see if it works.  If so then it’s one of two things. The brown wire feeding the relay is not getting 12v or the green wire is not getting a ground from the neutral safety switch. 
 

Double check the bike is in neutral before you do any of this. 
Check back and let me know. 
 

Ok so as you know my starter push button did not work. I spliced a wire from the starter switch to the black wire on the starter relay to bypass the starter circuit relay. This is the only wire that has changed. Now my push button works but I am not getting spark still. I have 2 starter circuit relays and I get no spark with either. What are the chances that they are both bad? They are both used. I just don't know how common it is for these to go bad considering how simple they are. I'm literally to the point of swapping a predator 420 in this thing if I can't figure it out soon. I do get the neutral light by the way. I'm really stumped and frustrated. 

Well, I now have spark! But only pull start. I hooked up my starter relay and tested it. It works, but nothing from the push button. I took it apart and cleaned the contacts. I get no continuity with the button unpressed and continuity when pressed so to me that means the button it good. Could this be a starter circuit relay issue?

Perfectly clear. I'm mostly frustrated because I'm not used to having issues like this lol. I'm no bewbie to wiring at all. I have built several GY6 and CN250 builds and built custom harnesses by hand, as well as build several Honda's for racing and custom built those harnesses as well. So, in theory, this should have been a breeze. 

Well then I'm still without spark. So, I know my pickup coil was bad. I happened to have one from a CN250 (GY6 style) that looked the same so I used it. I'm thinking maybe it just isn't working with that engine. I don't know what else it could be. I'm getting headlight, and indicator lights. My CDI should be good because I pulled one off of a Bayou 250 just one year newer. Same with the rectifier. I'm starting to dislike this ATV.....

Just hanging. I thought maybe the red recharged the battery. It looks to me like the battery get recharged via the white wire. Is this correct?

*EDIT* I see the terminals in one of the diagrams I have. I just missed because in my diagram it is toward the front of the vehicle.

My headlights work. Should I check somewhere else?

Also, my indicator lights work. 

All open line and no continuity. I'm so stumped. Now I will say that I do not have the starter relay on it. It is still in the mail. But I do have the white wire that goes to the relay hooked straight to the positive side of the battery

Thank you for your help. So far I have it wired correctly but still no spark.  I know the pick up coil to be bad so I replaced it and yet still no spark. I have pretty much replace everything except the stator. Would a bad stator cause a no spark issue? I'm getting 0.7 ohms of resistance between the yellow wires from the stator. 

Thank you for your help. So far I have it wired correctly but still no spark.  I know the pick up coil to be bad so I replaced it and yet still no spark. I have pretty much replace everything except the stator. Would a bad stator cause a no spark issue?

It is not new. If fact, I think it is the original 1998 coil. I'm getting no more that 15.8 ohms of resistance. Should it not be more like 130 to 150? That's what it is on my buggy. But that is a1 50cc GY6.

Should I be getting continuity between the 2 pickup wires? I do on all my other vehicles but not this one. Maybe bad pickup?

This is the ignition switch that was on it. 

Ok try to walk me through this. First of the CDI from my 250 had the same numbers on them as this 220. The 250 has no grey wire in the harness and the 220 does. My ignition that came from my 220 had/has a brown wire and a white wire. Now when I wire the brown and white together to complete the circuit, my neutral light comes on as intended. So it seems to me that this is correct. Also, that diagrams shows a yellow/red wire going to the ignition and I do not have a Yellow/Red wire up front. It's not even in the legend call out in that diagram either. Is the KLF different than the Bayou? 

This is even more confusing. On top of the fact that my ignition is 2 wires and not 4. My CDI box doesn't even have a 7 pin plug. Only 6. 

Thank you. But could you please explain the ignition wires? I have a brown and white wire. when I hook up the ignition, the neutral light comes on like it is supposed to. Also my other quad does not have that wire. Thanks. 

Also, I am not getting continuity between my two pickup coil wires.

2 hours ago, Frank Angerano said:

That grey wire goes from the cdi to the ignition switch.   

I don't see that wire in any diagram. Also, my ignition was only 2 wires. A white and a brown. Also, I have a 1999 Bayou 250 as a parts bike and it doesn't even have that wire. Can that wire be deleted?

Actually there is one other thing. I have seen a few diagrams and they all have 5 wire CDIs. My has 6 wires. I have a grey wire that has been cut. What is this wire for?

Still no spark. I know I have the wiring right. Coil maybe?

Thanks. It's a 220. I don't have the ignition because it was taken off. However I have the brown and white wire connected to each other to complete the circuit. I do not have the starter relay yet. It is on order. I'll check back in once I have the stuff. 

22 minutes ago, Frank Angerano said:

Hey @Andrew Baker welcome to Quadcrazy. So what’s going on with the harness you said it’s hacked up pretty good.  Do you know whats missing or disconnected etc ? I can help you out but need to know what’s left of the harness and where you need help. If you can, post a few pics of the areas that are hacked up and in the meantime I will get you a diagram to help you along so you can figure out what’s going on.   

Thanks. So, the wiring that goes to the starter solenoid and the battery is snipped. It seems that the red feeds the lights and the Black/Yellow is ground. I know that one Black/Yellow, White, and Black will go to the solenoid, and IF the Red feeds the rear lights then that leaves 2 Black/Yellows. Is that the ground for the rear lights? I guess my main question is, would not having all the grounds prevent me from getting spark? I thought the spark would be generated directly from the flywheel trigger. But then again, most of my experience with this stuff is on cars and not ATVs. Especially non Chinese ones. 

I need help with wiring on a 1998 (I think, 10th digit of the VIN was W) Bayou. I'm not getting spark, I'm pretty sure it is due to grounds being off because the harness is pretty hacked as far as the electric start and charging system goes. I'm needing a good wiring schematic. I found one online and there are a few things that don't add up on it so I'm skeptical that it is really for my year and model. Any help would be appreciated. Thanks.