Hello all. First time poster. Been reading the board for a couple of days now and can't find what I'm looking for.
Can anyone tell me where I can get a starting relay and a wiring diagram for a 1999 Sundiro 90cc Sunray ATV? A fellow gave me the little ATV. He installed a push button switch to bypass the handle bar starter button. The atv will start and run but is extremely cold natured. It has an electric choke. I am assuming that by bypassing the starting relay the electric choke no longer works.[img]i/expressions/face-icon-small-confused.gif[/img]

 

well find the wire going to the choke actuator and hook a puch buton up to it to.one wire will go to power to choke and the othere will be always grounded. find the grounded one with you multimeter on ohms. or see if you can rip that crap out of there and make some sort of deal you can flip with your fingers to choke manualy like most bikes have. are you sure it had a electric choke?

you got tools?

 

It most definitely has an electric choke. I'm sure I can pull it off the carb and install a manual choke if I knew where to buy one for this type atv. Choke attaches to the carb with one screw has an electic solenoid mounted to the top of it instead of the cable you would have on a manual choke. Can't remove the solenoid and install a cable as it's all built together. Also looking for the non split throttle cable. Oil injection tank was busted so I trashed it and premixed the gas at 32:1.

 

any of the miniatv performance shops will have a single-pull cable. i prefer the Terry Cable brand.

re the electric choke, a push button will not work - it has to have electric power to it all the time, if not it'll default to rich mode.

the way it works is the electrical power does two things: it warms a wax material that when solidified holds the choke in the fuel-enriched ("choked") position; the other thing it does is powers a solenoid which tries to pull closed the needle which controls fuel flow through this circuit. the electric power is actually supplied directly by the lighting coil output of the stator, so its only powered when the machine is running. when the quad is cold the wax holds the needle in the rich position. eventually the heating coil in the choke is enough to loosen the needle and the solenoid pulls it closed and shuts off the extra fuel. if you shut off the machine hot, the needle springs back to rich. if you restart the quad hot, the solenoid immediately closes the circuit. but if you wait long enough the wax solidifies and holds it rich during the next startup.

the only failure mode that i can envision related to the choke that would cause hard starting is if the needle stuck in the closed position, or that circuit has become plugged somehow. otherwise, i would look at compression, fuel quality (old), and weak spark. if it starts ok, but bogs when given throttle, your fuel mixture is lean and needs adjustment.

 

I appreciate the info on the electric choke. Now, can I pull the electric choke off the carb and directly replace it with a manual one (if i can find one somewhere)?
GEO can you list some websites of miniatv performance shops?
And back to the original problem Does anyone know where I can get a new starter relay from? I tested the relay and it is bad. I would really like to do away with the added push button starter and get the handlebar mounted starter button working like it is supposed to.