KAKO Complete Wiring Harness Kit User Manual

Product Overview

This KAKO Complete Wiring Harness Electrics Wire Loom Kit is designed for electric start upright engines commonly found in Chinese-made ATVs, Quad Bikes, Dirt Bikes, Pit Bikes, and Go Karts. It provides a comprehensive set of electrical components necessary for the proper functioning of your vehicle's ignition and electrical systems.

The kit includes essential parts such as the wiring harness, CDI, spark plug, ignition coil, solenoid relay, rectifier, ignition switch, multi-functional ATV switch, and magneto stator. This manual provides guidance on the components included, compatibility, and general installation considerations.

Product Components

The KAKO Complete Wiring Harness Kit includes the following components:

• 1x ATV Wiring Harness
• 1x CDI (Capacitor Discharge Ignition)
• 1x Spark Plug
• 1x Ignition Coil With Lead
• 1x Solenoid Relay
• 1x Rectifier (Voltage Regulator)
• 1x Ignition Switch (with 2 keys, waterproof)
• 1x Upgraded Multi-functional ATV Switch
• 1x Magneto Stator (6 Pole 5 Wire, 2 fixing holes)

Figure 1: Overview of all components included in the KAKO Complete Wiring Harness Kit, clearly labeled for identification.

Figure 2: The complete KAKO wiring harness kit, showcasing all included parts such as the wiring loom, ignition components, and control switches.

Compatibility

This wiring harness kit is suitable for a wide range of Chinese-made electric start upright engines, specifically 50cc, 70cc, 80cc, 90cc, 100cc, 110cc, and 125cc engines. It is designed for GY6 4-Stroke ATVs, Coolster, Quad Bikes, Dirt Bikes, Pit Bikes, Go Karts, Kawasaki KLX, 4 Wheelers, Scooters, Buggies, Motowork, Dune, and Taotao models.

It is compatible with engines from brands such as Lifan, Loncin, Ducar, Shineray, Zongshen, YX, Atomik, Pitpro, Hummer, Orion, Xmoto, Lei, DMX, SWD, TDR, DDR, Tommahawk, Monsoon, Grudge, Kazuma, Bull, Trooper, Hunter, Motox, Trojan, Blitz, Crusade, Link, Bigfoot, Kuda, Motoworks, Nitrous, Reign, Fury, Prox, Raider, Thumpster, and Thumbstar.

Important Note: This kit is NOT suitable for GY6 engine motorbikes or other Mini ATV/QUAD 150CC, 200CC, 250CC, 300CC models that utilize a different stator or CDI. Please compare your existing stator and CDI with the components shown in the product images to ensure compatibility before purchase.

Setup and Installation

Installation of this complete wiring harness kit requires careful attention to detail and a good understanding of electrical systems. Due to the complexity of vehicle electrical wiring, professional installation is highly recommended.

Before beginning installation, it is crucial to:

• Review the Wiring Diagram: Always consult a detailed wiring diagram specific to your vehicle and this kit. Understanding the connections is vital for correct assembly.
• Verify Component Match: Ensure that all connectors and components align with your vehicle's existing setup.
• Safety First: Disconnect the battery before working on any electrical components to prevent short circuits or electrical shock.

Warning: False or incorrect assembly of the wiring harness can lead to electrical malfunctions, component damage, or even fire. If you are unsure about any step, seek assistance from a qualified mechanic.

Figure 3: The main wiring harness, showing the array of connectors that need to be correctly identified and connected during installation.

Figure 4: The magneto stator, a key component for generating power, which must be correctly installed and wired.

Operating Considerations

Once correctly installed, the wiring harness kit facilitates the proper operation of your vehicle's electrical system, including ignition, lighting, and charging. The multi-functional ATV switch provides control over various functions such as lights and engine kill switch, depending on your vehicle's specific setup.

Figure 5: Key operational components: the multi-functional switch for controls, the solenoid relay for starting, and the rectifier for voltage regulation.

Maintenance

To ensure the longevity and reliable performance of your wiring harness kit, regular inspection is recommended. Check for:

• Secure Connections: Ensure all electrical connectors are firmly seated and free from corrosion.
• Wire Integrity: Inspect wires for any signs of fraying, cuts, or heat damage.
• Component Condition: Periodically check the physical condition of components like the CDI, ignition coil, and rectifier for any visible damage.

Keep the electrical components clean and dry to prevent issues caused by moisture or dirt.

Troubleshooting

If you encounter issues after installation, consider the following troubleshooting steps:

• No Spark/Starting Issues:
  • Re-verify all connections against the wiring diagram.
  • Check the spark plug for proper gap and condition.
  • Inspect the CDI and ignition coil connections.
  • Ensure the magneto stator is correctly installed and functioning.
• Electrical Malfunctions (e.g., smoking wires, blown fuses):
  • Immediately disconnect power.
  • This often indicates an incorrect connection or a short circuit. Thoroughly re-check the wiring diagram and all connections.
  • Ensure the correct voltage regulator (rectifier) is used and properly connected.
• Component Fitment Issues:
  • Some older or non-standard models may require minor adjustments to pin configurations in connectors. Refer to a vehicle-specific wiring diagram.
  • Ensure the stator type (e.g., 6 pole 5 wire) matches your engine's requirements.

If problems persist, it is advisable to consult a professional mechanic or an experienced electrical technician.

Specifications

Customer Satisfaction & Support

KAKO is committed to customer satisfaction. If you are not completely satisfied with your purchase, you may return it within 30 days for a refund or credit. For any technical assistance, installation queries, or product support, please contact the seller directly through your purchase platform. It is recommended to have your order details and product model number ready when seeking support.