I have a Sunl 150-2A buggy, it just stopped working one day. I have narrowed down somewhat and need some help with the rest. I have it down to having to manually object all three ignition wires and it will start but as soon as the starter disengages the buggy dies. It will run all day as long as all three wires are connected, but not good for the starter to run all the time. Any ideas please.

 

I'm not familiar at all with a sunl buggy.

1) On your ignition switch there are three wires? Or are there more and you are only connecting three wires?

2) What are the colors of those wires? And please (this is really important) report *only* the wire colors on the main wiring harness side of the connector to the ignition switch. The short pigtail wires to the ignition switch itself are completely irrelevant.

3) When you go to start the quad what engages the starter motor? Is it connecting the three wires above? Or do you have to connect the three wires and then push a "start" button?

4) Find your CDI. How many pins? Is it four pins, five pins, or six pins (six pin CDIs have 2 connectors, a two pin and a four pin).

 

There are only 3 wires at the key switch and from what I can see 1 is hot which I think is either green or gray with a yellow stripe, sorry colorblind. The second one is solid gray or green and that cranks the starter when powered. The third is black and needs to be connected to start the buggy. I'm thinking the way it should work would be that the key would turn to acc and power the black, turn the key to start and the ugly would start and when you turn the ignition back it would stay running by having power to the black wire, which does not happen.

The CDI box is a six wire 2 connector.

I can send pics if that helps.

 

I'm wondering the following...

Suppose your wires are actually like this:

Solid Gray or Green: 12 volt fused power from the battery
Green or Gray with a Yellow Stripe: Power to the starter motor circuitry
Black: Power to the ignition system

Note how this is backwards from where you had 12 volts from the battery coming in on the Green or Gray with a Yellow Stripe wire. If the wiring is actually like my scenario above then when you think you're disconnecting the starter motor wire (to stop the starter from turning) you're actually disconnecting the hot wire which sends power to everything - including the ignition. So what happens if you short all three wires together to crank the starter, then disconnect the Green or Gray with a Yellow Stripe wire to stop the starter motor? Does it work now?

So how did you determine which wire is always hot, and which wire powers the starter, etc. Did you use a meter?

Once we verify the function of the three wires above, then if that doesn't point to the problem the next step will be to measure the ignition system to figure out why the spark stops when the starter is shut down. You'll need to get that meter ready...

 

I used a power probe to determine which was hot, I was informed by my friend who is the owner that he replaced the cdi box as well as the coil, what I found out was that the coil he bought was he wrong one and never replaced. Do you think this could be the issue? I also was not sure if it could be grounding out some where.

 

No, I don't think that the ignition coil has anything to do with your problem. The quad starts up and runs. Then you disconnect the starter and it stops. It's got to be that when you think you are disconnecting the just starter you are disconnecting much more than that.

I would double check the colors of the hot wire, versus switched hot wire, and starter activate wire. It is so easy to get something wrong, and then get led down the garden path. If those two wires in my last post were misidentified it would explain *precisely* what you saw.

I would almost bet that is the problem, since it is by far the simplest solution (considering Occam's Razor and all...)

But lets say it's not the problem. Does your CDI look like this?

 

I will double check the connections and yes that is my CDI.

 

I think I may have figured out my issues, the issue was two fold, you were correct on the ignition I did have the wrong wires, sorry for that. I also had a fuel issue I did not think there was a fuel issue because it would to start with direct fuel or starting fluid.

I to fuel to it and checked the plug for spark when i had spark I put it back together and it fired. Now I just need To figure why the ignition does not work. I can wire them together to start it but when connected to the ignition it does not even crank. I guess it will have to wait for the weekend.

Thanks for all your help!!!!!!

Mike

 

I'm glad you got the wiring part figured out.

Your ignition switch is probably just bad.