OTOHANS AUTOMOTIVE B0CDWKBQRB

OTOHANS AUTOMOTIVE Complete Electrics Wiring Harness Instruction Manual

For 4 Wheelers Stroke ATV 50cc 70cc 90cc 110cc 125cc Go Kart Pit Quad Dirt Buggy Bike Parts

1. Product Overview

This OTOHANS AUTOMOTIVE complete electrics wiring harness kit is designed for electric start upright engines commonly found in Chinese-made ATVs, Quad Bikes, Dirt Bikes, Pit Bikes, Go Karts, and similar vehicles. It is compatible with 49cc, 50cc, 70cc, 80cc, 90cc, 100cc, 110cc, and 125cc engines.

The kit provides essential electrical components to replace or upgrade your vehicle's wiring system, ensuring proper ignition, charging, and starting functions.

Complete Electrics Wiring Harness Kit components

Image: Overview of all components included in the OTOHANS AUTOMOTIVE Complete Electrics Wiring Harness Kit.

2. Safety Instructions

Adherence to these safety guidelines is crucial to prevent damage to the harness, vehicle, or personal injury.

  • Correct Relay Connection: The relay terminal must be connected to the positive pole. Connecting it to the negative pole will cause the relay to ignite and potentially burn out the entire circuit.
  • Battery Polarity: Ensure correct connection of positive and negative battery wires. Reverse connection can cause the electrical system to burn out.
  • Professional Installation: If you are unsure about the wiring or installation process, consult or hire a qualified mechanic. False assembly can lead to fire hazards.
  • Regular Inspection: Periodically inspect all components for signs of wear, damage, or insulation degradation. Replace any worn or damaged parts promptly.
  • Solenoid Maintenance: Regularly clean the solenoid to remove dust, dirt, or contaminants that could impair its performance.
Wiring diagram with safety instructions

Image: Detailed wiring diagram with important safety notes regarding connections.

3. Package Contents

The OTOHANS AUTOMOTIVE Complete Electrics Wiring Harness kit includes the following components:

  • 1x ATV Wire Harness
  • 1x CDI (5Pin AC)
  • 1x Solenoid Relay
  • 1x Rectifier (Voltage Regulator)
  • 1x Ignition Switch (with 2 keys, waterproof)
  • 1x Upgraded Multi-functional ATV Switch
  • 1x Stator (Magneto Generator)
  • 1x Ignition Coil with lead
  • 1x Spark Plug
  • 1x Fuse
  • 10x Cable Ties
Labeled components of the wiring harness kit

Image: Labeled diagram of the various components included in the wiring harness kit.

Spark Plug, CDI, and Rectifier components

Image: Close-up view of the Spark Plug, CDI, and Rectifier components.

4. Setup and Installation Guide

Before beginning installation, carefully review the provided wiring diagrams and ensure the vehicle's battery is disconnected. It is highly recommended to check the pictures and wiring diagrams thoroughly before starting.

4.1. General Wiring Connections

  • Battery Connection: The red wire of the harness is the positive pole, and the black wire is the negative pole. Connect these directly to the corresponding battery terminals.
  • Solenoid Relay: Connect the solenoid relay according to the wiring diagram. Ensure the relay terminal is connected to the positive pole to prevent ignition issues.
  • Stator (Magneto Generator) Wiring:
    • Red and Black wires: Ignition wires.
    • Blue and White wires: Trigger wires.
    • Double Yellow wires: Charging wires, connect to voltage stabilizers.
    • Green wires: Grounding wires.
  • Ignition Switch: Connect the ignition switch. This kit includes a waterproof ignition switch with two keys.
  • Multi-functional ATV Switch: Install the multi-functional ATV switch on the handlebars.
  • CDI and Rectifier: Connect the CDI (5Pin AC) and Rectifier (Voltage Regulator) to their respective harness connectors.
  • Spark Plug: Install the spark plug into the engine cylinder head and connect the ignition coil lead to it.
  • Fuse: Ensure the fuse is properly installed in its holder within the harness.

4.2. Important Considerations

  • Wiring Diagram Verification: Always cross-reference your vehicle's existing wiring with the provided diagram to ensure compatibility and correct connections.
  • Brake Switch Safety Feature: Some ATV models require the brake switch to be engaged to provide power to the starter. If you experience no power to the starter after installation, check the brake switch wiring and ensure it is properly connected or bypassed if your vehicle does not have the corresponding receptacle.
  • Wire Lengths: Be aware that some wire lengths may vary slightly from original harnesses. Plan your routing accordingly.
Detailed wiring diagram for installation

Image: Comprehensive wiring diagram to guide the installation process.

4.3. Installation Video Guide

For a visual guide on the installation process, please refer to the official product video below:

Video: Step-by-step installation guide for the OTOHANS AUTOMOTIVE Complete Electrics Wiring Harness.

5. Operating Instructions

Once the wiring harness is fully installed and all connections are secured, you can proceed with testing the system.

  • Ignition: Insert the key into the ignition switch and turn it to the 'ON' position. Verify that the vehicle's electrical system receives power.
  • Engine Start: Engage the brake (if required by your vehicle's safety system) and press the starter button on the multi-functional ATV switch. The engine should crank and start.
  • Kill Switch: Test the kill switch function on the multi-functional ATV switch to ensure it properly cuts off engine power.

Ensure all connections are tight and secure before operating the vehicle.

6. Maintenance

Proper maintenance extends the lifespan of your wiring harness and ensures safe operation.

  • Visual Inspection: Regularly inspect the entire wiring harness for any signs of wear, fraying, cuts, or exposed wires. Check connectors for corrosion or looseness.
  • Component Check: Examine individual components like the CDI, rectifier, solenoid, and switches for physical damage or signs of overheating.
  • Solenoid Cleaning: Keep the solenoid free from dust, dirt, and other contaminants that can accumulate and affect its performance.
  • Replacement: Immediately replace any worn-out, damaged, or malfunctioning components to prevent further issues or safety hazards.

7. Troubleshooting

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

ProblemPossible CauseSolution
No power to the starter/engine won't crankIncorrect battery connection; Faulty ignition switch; Brake switch not engaged (if applicable); Loose connections.Verify battery positive (red) and negative (black) connections. Check ignition switch functionality. Ensure brake switch is engaged or bypassed if necessary. Inspect all harness connections for tightness.
Engine cranks but won't startFaulty spark plug; Incorrect CDI connection; Stator issue; Fuel delivery problem (not harness related).Check spark plug for proper function and connection. Verify CDI connections. Inspect stator wiring. Ensure fuel is reaching the engine.
Harness overheating or burning smellIncorrect wiring (e.g., reverse polarity, relay terminal to negative); Short circuit.Immediately disconnect battery. Re-check all wiring against the diagram, paying close attention to battery and relay polarity. Identify and rectify any short circuits.
Components not functioning (e.g., lights, horn)Loose connections; Faulty component; Incorrect wiring for specific accessory.Check all connections related to the non-functioning component. Test the component if possible. Verify wiring against the diagram.
Wiring colors do not match original harnessUniversal harness design.Refer strictly to the provided wiring diagrams for this specific kit, not your old harness's color scheme. Use a multimeter to confirm continuity if unsure.

If problems persist after troubleshooting, it is advisable to seek assistance from a professional mechanic.

8. Specifications

This section provides detailed technical specifications for the OTOHANS AUTOMOTIVE Complete Electrics Wiring Harness kit components.

8.1. General Harness Parameters

  • Working Temperature: 90 °C
  • 0.3 Wire Passing Current: 1.8A
  • 2.5 Wire Passing Current: 28A
  • Vehicle Working Voltage: 12V

8.2. Component Specific Parameters

  • Rectifier:
    • Temperature: -40 °C to -80 °C
    • Voltage: 12V-24V
    • Output Voltage: 14.5 ± 0.5V
  • Magnetoelectric Coil:
    • Output Voltage: 15V-22V (varies with speed)
    • Current: 4A-7A
    • Power: 100W
  • Function Switch:
    • Voltage: 60V
    • Current: 20A
    • Power: 1000W
    • Working Temperature: -10 °C to -60 °C
  • Solenoid Relay:
    • Working Voltage: DC 12V
    • Working Current: DC 150A (30S)
    • Working Temperature: -10 °C to -80 °C
    • Power: 200-500W
  • Ignition Coil:
    • Working Temperature: -40 °C to -100 °C
    • Voltage: 12V-16V
    • Current: 1mA
    • Power: 300-350W
    • Output Voltage: 15000V
  • CDI:
    • Temperature: -40 °C to -60 °C
    • Voltage: 6V-24V
    • Current: 2A
    • Power: 12-48W
  • Switch Key:
    • Copper Wire Withstand Current: 1.5A
    • Voltage: 12V
    • Temperature: -40 °C to -60 °C
    • Power: 18W
Dimensions of various wiring harness components

Image: Dimensions of key components for reference during installation.

9. Warranty and Support

Specific warranty details for this product are not provided in the available information. For any questions, technical assistance, or support regarding your OTOHANS AUTOMOTIVE Complete Electrics Wiring Harness, please contact the seller directly through the platform where the purchase was made.

You may also visit the OTOHANS AUTOMOTIVE Store for additional product information or contact options.

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