Hello, I have a SUNL ATV with an electrical issue. It ran perfectly but I lost they key. I tried crossing a couple wires on the ignition, the wires sparked, but nothing else. Now it won't start. I found the key a week later but now it won't turn over at all. The battery has power, there is power to the starter, the two fuses I could find look good. There is some black box that a lot of the wires run into. Not sure what that is.

Now what? How can I find out where the problem is? How can I fix it? Can I bypass the ignition part? Any suggestions would be much appreciated. Thanks

 

How namy wires are on your ignition switch, and what are the colors? Don't report the colors on the short pigtail wires from the switch - I need the colors of the wires that they connect to in the main wire harness.

The ignition switch usually has 4 wires, and two of those wires are +12 volts and ground. If you try to cross those two you'll get sparks - and usually blow the main fuse right near the battery (or on some quads the fuse is part of the starter solenoid assembly).

What are the values of the two fuses you did find?

What about lights (headlights, brake light, tail lights)? Do they work? Does anything electrical work when you turn on the ignition switch?

With the above info the next step is to use a meter to follow the power path from the battery to/from the main fuse, to the ignition switch, and out the "ignition on" side of the ignition switch.

So let's start with the above questions, and have a meter at the ready for the next steps...

 

Ok, not my brightest moment. I looked at those fuses multiple times but didn't realize the cartridge fuse was blown until I took it out to check the amps. Anyway, I have it running again but wondering if you have some advice on how to troublshoot the headlights. The brake lights work and If I connect the headlight wires directly to the battery, they do turn on so the lights themselves are fine. There are 3 wires coming from the headlight that run into the main wires.

 

Do you know if your lights are powered by 12 volts DC or by AC voltage coming directly off the stator? DC powered lights normally work when the ignition is on, and the headlight switch is on, even when the engine is stopped (and/or running). AC powered lights work only when the headlight switch is on and the engine is running. AC powered lights are always off when the engine is not running. AC powered headlights are usually dim at idle and brighten up with faster engine speed. Both topologies are common.

Have you ever seen this quad when the headlights were working? If so, how did they work? AC or DC? Note that the headlights and tail light may or may not run off AC power, but the *brake light* always runs off DC power since it is part of the brake switch/starter motor safety interlock system.

 

Having some Sunl wiring trouble myself. My nephew was riding it ran great, He shut it off and then went to re start it and nothing. No lights will even light up. I have twelve volts to the battery side of the solenoid noting on the starter side. Went up to the key and tested the Red wire on the machine side of the plug and on power there either,, Any thoughts out there. I don't have a wiring diagram to go by so making trouble shooting a bit difficult