The wires are good yea. ive checked almost all of them.


Oh, well there is 5 other wires coming out of the engine. We figgured out these are gear indicators.


Yes, the fuse will be done!

but since the color of the wires from the stator and the regulator dont match the ones on the wiring diagram. what should i do?

 

mark them the way you can remember them. wire "a" goes from point a to point b.
wire "b" goes from point c to point d
so on and so forth. as long as you can differentiate between the wires and what they're doing and where they're going, color of the wire shouldn't be an issue as long as you draw up your own legend and mark the wires so you can assure yourself what is what for any future reference. that's my two cents.

 

Ok so i did som wiring today and i actually got it started with some startgas

This picture shows how i did it:



The remaining 3 wires from the regulator and the 2 from the stator are the ones i didnt know where to connect. So i sort of wired them randomly and tried

I left one from the regulator and wired the two others.
It didnt seem to have any effekt on the startup, so what does these wires between the stator and the regulator really do?

 

I will reply tomorrow when I get back. I'm in a hotel with unbelievably bad internet access. I think the entire hotel is sharing a 300 baud modem .

This problem is easy to answer.

 

ok
No problem

 

The regulator has nothing to do with whether the quad cranks or starts. The regulator has the task to take AC power from a winding(s) on the stator, rectify it to DC, and regulate it so that it can power all the 12 volts stuff on your quad when the engine is running, and have a little excess output power keep the battery charged. If you unplug the regulator the quad will still start and run fine - for a while. All the 12 volt stuff will still work (headlights, brakelights, horn, starter motor, starter solenoid, gear indicators, neutral lights, etc) because it will just run off your battery. But your battery isn't being recharged, and it will eventually go dead. It may take a long while (days) unless you start the quad up frequently or run the headlights. Of course when you battery is dead it won't start, and since it is a slow death process the battery is damaged a bit by not being kept charged up to maximum.

It's kind of like your car charging system, except there is a light on your car that warns you when your charging system isn't working. It usually say "alt" or something. There isn't a warning like this on chinese quads (and maybe most quads).

SO you have to measure this yourself:

Start up the quad, turn off the headlights, and raise the engine to a medium fast engine speed (in neutral of course). Measure the DC battery voltage right on the battery terminals. If you get 13.5 to 14.5 volts DC then your charging system is working. Your wiring is correct, and you can rest easy.

If not we need to look further...

 

oooh ok, i understand thankyou!

Oh ok, actually we didnt wire any light or anything yet. we figgured it was easier to run an separate system for the lights and so

Ok, il do some measuring tonight and see what i can find out!


We got it running properly yesterday. so now it runs fine

Its almost time to take it apart and restore it. thats the part we know how to do

As long as we can find parts that fit. Like fenders and so. if not i think we will find something simular and custimize the frame alittle so it fits

 

Here is a video of the first startup:



we figgured out that we will start working on the frame now and fix it up before we make the wiring complete. now that we know it works, we can finish the bodywork so we dont need to take it apart after finishing the wiring

Got started on the the frame yesterday, here are some pics:





We are sanding the whole frame down so the paint will sit properly. its starting to get somewhere


Thankyou guys for your help. It helped alot!

 

Nice pic's...

 

Hey I have just got a atv just like the one you post pictures of and the harness I was given is a big mess! And I can not find anything anywhere on a wire diagram for this motor I have gotten it to turn over but mo spark because somewhere something is wired wrong and I also dont know what wires are for the clutch , I was hoping you would be able to send me a picture or a link to where I can find a wire harness diagram I can redo all the wiring
thanks