I bought a new 110cc motor for this go kart, installed it and it runs great. Now my gauge on the dash that tells you what gear its in is not insync with the motor. Guage says its in 2nd gear and the motor is in neutral. Second question is: i get a clicking noise when i try to start the go kart with the key. I have a new stator, new cdi and voltage reg. the clicking seems to be coming from a relay. so i changed the relay and the new dose the same clicking noise. any ideas???

 

someone may have wired the relay wrong. Take a test light and look for the hot pin when you are trying to start. They may have gotten a few wires backwards. you can also look on the relay for the wiring diagram if you understand that type of thing

 

I did that and no power coming out of the relay. I also check the ohms on the relay and everything checks out ok. Still notheing.. So, i took two small cotter pins and made jumpers out of them to bypass the relay without cutting wires and BAM it starts right up… So, now, why does this go kart need a relay? any idea??

 

a relay reduces the load on the starter switch/light switch etc. it takes a normal voltage that triggers the relay and then the relay gets power direct from battery once triggered to power the destination like a starter or lights. Im thinking that the relay is getting a signal from both your starter switch and possibly your trans neutral switch (probably the ground for neutral switch) but don't quote me on that. You ether need to trace out the issue with the dash showing the wrong gear or try to figure out what pin it goes to on the relay and bypass it temporarily. Not sure how the neutral switch works on your machine but for most things they will not start in gear.