on a 90cc falcon,there are a couple of wires(color coded) that come out of the case.can anyone help in identifying them and what they go to.thanks

 

How many wires? What are the colors?

When reporting colors be sure to use the colors in the main wiring harness instead of the pig tail wires going into the engine. The pigtail tend to vary from quad to quad, and if they don't match the wiring harness colors then we can't determine where the wires go. That is why we pay attention to the wiring harness colors. I/E: If in the main harness a pink wire enters the harness it will still be pink when it comes out some where else. This is valuable information.

 

out of the magneto case, i have the following.
wires
blue with white stripe
solid green
solid white
solid yellow
and black with red stripe.
im looking to identify what purpose each wire serves.all i have on the quad is the coil and keyswitch.if im reading the diagram correct,all i have to do is power a cdi,and coil to make this thing run?i dont have a harness so im just lookin to see what i need to power these components and then move on.

 

blue with white stripe <=- Timing trigger to CDI
solid green <=- Ground
solid white <=- Low voltage AC to voltage regulator #1
solid yellow <=- Low voltage AC to voltage regulator #2
and black with red stripe. <=- High voltage AC power to CDI (100-300 VAC)

Why not buy a wiring harness? I haven't looked to see if they are readilly available for your quad, but if they are they are usaully cheap. And it will problably cost less overall than the wire and stuff you will need to buy to wire up just the minimum functions, and then replace all the stuff you screw up in the process (let's be real here - nothing goes according to plan...).

That's not to say that replacing the harness will solve all your problems, but IMHO I think it will be the easiest and less costly course overall.

I'll help as best I can either way, but most people who go the "I'll wire up everything manually" route give up mid way and have nothing to show for their efforts in the end.

How are you going to connect to all the pins/terminals without connectors? How's your soldering? Got a meter? Once you get the ignition circuitry running, what about the battery charging system? Are you going to start this quad with a screwdriver across the solenoid, or get a start button working?

I'm not trying to discourage you, just get some reallity checks in place.

 

i understand but the harness is over a hundred dollars.all the wiring/hardware i stock.i have the key switch so i was just ginna start off of a button wired in.

 

To get spark you need to wire up the CDI with:

1) Timing Trigger
2) CDI Ignition Power
3) Ignition Coil
4) Ground

Once the quad starts you need some way to shut it off (removing the battery won't do it):

A) Kill switch pin on the CDI needs to be shorted to ground through one half of the two section ignition switch. When ignition switch is off (kill switch section shorted) there will be no spark, when the ignition switch is on (kill switch section open) there should be spark whenever the engine is turning.

Look at the following pic of your CDI:



1) Timing trigger pin is Blue/White - wire it to the blue/white out of the stator.
2) AC Ignition Power is Black/red - wire it to the Black/Red out of the stator.
3) Ignition Coil pin is Black/Yellow - wire it to the black yellow on the ignition coil.
4) Ground is green wire it to Ground
5) Wire the kill switch pin to the Black/White wire on the ignition switch.
6) Hook up several grounds:
a) Green on the coil gets wired to ground
b) Green on the ignition switch gets wired to ground
c) Green coming out of the stator gets wired to ground.

The ignition circuitry is now wired up. To start the quad you will need the starter to turn. Take a screwdriver and short across the two big starter solenoid posts. Does the starter turn? Of course you'll need a good battery for this.

This is just a start.

Ignition system first, then starter motor stuff using the ignition switch and the start button, then the battery charging system. In the mean time keep your battery charged with a maintenance charger.

 

thanks a million.i rebuilt the satrter and bench tested it so thats out of the way.i have good compression so once its wired il throw up some pictures.thanks again
jonny