Quantcast
Jump to content

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
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
Strike37G Rookie

Strike37G

Posted
  • Author
Posted

Nothing from the Yamaha harness is in play. Its literally a new harness. The wiring "diagram" is really crude and didn't show where each of the stator wires went. im going out on a whim the 6 pin plug coming from the engine is a neutral light.

processed-5171a6da-7249-4960-aaee-e9702e2f2eb4_m3PGk25L.jpeg

processed-608ca951-92b0-4914-a969-9de068d2b463_mwNlWZs1.jpeg

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
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.

  • 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

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

    • AnthonyT
      First time ATV buyer
      By AnthonyT
      In search of my first ATV? What are good older 4x4 models?
    • 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.
       
    • Frank Angerano
      My first trailer project.
      By Frank Angerano
      So I decided to pick up a small trailer if I could get one for the right price.  I found this one for a few hundred bucks on Craig’s list.  It is  a galvanized trailer which is exactly what I was looking for. The wood was shot and needed some minor repairs which I could care less about as long as the chassis was good. 
      I striped it down and put a new deck on. I had some vinyl realtree graphics that I had laying around so I added them to the fenders which I think worked out well. Very happy with this little guy.  
      I'm having the iron workers at my jobmake me up a few lightweight side rails that will have a 22 degree bend in them to accommodate the tires that slightly hang over the edge and will incorporate some tie down points as well. 








    • Kaz
      1999 Yamaha Big Bear 350 4x4 no spark
      By Kaz
      Troubleshooting a no spark issue, was running OK, maybe a little rich, turned it off, now no spark. I've checked/ohmed out the main key switch, the start/stop switch, neutral switch, brake switch - all good. It will crank the starter, but no spark with the starter or when I try the pull start. I've checked all fuses and diodes. Swapped battery. New plug. New coil. Swapped in a used CDI - no help. Traced, removed, cleaned, reattached all grounds. Removed things like my winch from the circuits to be sure a bad relay or something was dragging it down. When testing voltages, the orange wire going from the CDI to the ignition coil shows no/very low voltage-shouldn't it have 12V on it? Sometimes I get a very weak, intermittent glow on my spark tester, but not enough to fire the plug. I've checked continuity on just about all wires in the harness. Checked/cleaned/lubed w dielectric grease- all connections, redid a few that looked old/dirty. I've checked the stator resistances, all good, but have a stator and rectifier ordered anyway, will arrive Sunday. I verified that the rectifier has a voltage output back to charge the battery while cranking - 10.5-11V, low, but expected while starter is engaged. What else can I check as part of troubleshooting? I have a Haines service manual, but the 1999 350 4x4 seems to be an odd model, there isn't an exact electrical diagram for it, but found one for another year that has all the same number of wires and same color wires, so I've referenced that. Any hints, tips or advice would be appreciated! Thanks!
    • fwsamm
      2001 Yamaha Bear Tracker Circuit Relay Issue
      By fwsamm
      Im aware that this relay needs a positive (+) and a negative (-) to activate the other side. The blue wire is the neutral wire so when in neutral it gets ground. The green wire is from the parking break; when you pull the break in it gets ground (-). however one of those two needs to be neutral so that the positive from kill switch can go to the starter relay. The ground from the starter relay is from the start switch. Which one (neutral or parking break) should have a positive (+) voltage?

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...