Go Kart 150 Wiring Harness from Scratch

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Go Kart 150 Electric Diagram
Go Kart 150 Electric Diagram

We made a video to explain how you can redo a full wiring harness for a 150 cc Go Kart. We explained every step, including the testing with a multimeter and the electric plan.

The wiring harness is a common problem with the 150cc Go Kart. After a few years, people will start having a problem with connections, bad ground, and anything that comes with it. We did a simple video to help people bring back their machine to life and give them a simple way to redo a full wiring harness. This video only includes the basic thing you need to start the machine, and it does not include headlights, turn signal, speedometer, and all other accessories your machine might have.

This video can be used to rewire an Ace Maxxam 150, Carter Talon 150, Hammerhead 150, TrailMaster 150, and any go kart that comes with a GY6 150.

This is the electrical plan we used: (If you need any parts, the plan is clickable and will bring you to our website).

Click on the picture to download the PDF

Go Kart 150 Electric Diagram
Go Kart 150 Electric Plan

Go Kart 150 Electric Plan / Wiring Harness Clickable

43 COMMENTS

      • I have a TrailMaster Blazer 4… And need some wiring help.. I can’t figure out how to connect my CDI.. wires were cut.. also no Idea is this is AC or DC.. any help will be very appreciated… I can buy the parts from the website… (No spark) to thanks

          • I also having an issue connecting my key switch.. I was trying to follow your diagram to make my go kart work. But the key switch is a 5 wire 🤔 switch and yours is only 3 (more simple) and easy to follow… What are the other 2 wires for?… Again thanks in advance… And yes is A DC

          • Found 2 types of 5 wires switch but there’s maybe more. Option 1, the key switch is the same but 2 wires are use to short the CDI and stop it from sending a signal the the ignition coil and stop the engine. Option 2, all basic 3 wires are the same, the other 2 are use when the machine is running, 1 wire is coming from the regulator and the other wire is going to supply more power to the machine when it run. You will need to test the switch and check where the wires goes to figure it out.

          • This is the comment you put on YouTube but can’t find it anymore. “Hi… I have the same engine on my TrailMaster Blazer 4. And the same wiring… Just the key switch has 5 wires… Instead of 3…. And I can’t make it work. What are the other 2 wires for? (Black,Red,Orange/Red, Black/White and Green) also all the 8 pole stators are the same or one is Ac and other DC??? Help please.”

            Green is usually ground. Black/White goes to the CDI. That might mean you have a AC CDI. When you will turn the switch to the off position, if you take a multimeter, you should have continuity between the green and black white. If yes, it is use to Kill the CDI from sending the signal to the ignition coil. As for the Stator, AC stator have 8 coils but 1 is use to the AC power the an AC CDI. The version that say DC, it mean all 8 coils are use to generate power and the CDI will be DC. You can still use an AC stator for a DC CDI but can’t use an AC CDI with a DC stator as you will not have the AC required to supply the AC CDI.

          • There’s anywhere I can send you pictures or a Video? I test the CDI of this Go kart on my other go kart (DC CDI) and it work.. all my wires are the same as the blue one on your video… (3 wires black/white) that test continuity with ground) red/orange to the solenoid, Green ground, Red to battery, black/white to CDI and splits in 3 in the back,and also black going to CDI.. Sorry for so many questions…

  1. How much would you charge to make this wiring harness for a car meter 150? Mine is trashed and I am not good at anything electrical.

  2. i need to do the same to my 2016 kandi so if u could point me the way of buying all the stuff i will need would help me out thanks

  3. So I’m replacing the wire harness and for some reason the black/red wire has continuity with the key switch off and I don’t know why

  4. Thanks for your Time and Help on Your Training video, I’ve got this Kandi CKndx.150GKA 149cc
    Go cart, It has no stop button, it has a looks to be a headlight relay, where can I found the correct wiring diagram?
    Thanks , I can not get the engine to turn over.

    • Thanks, happy it help peoples.

      The stop button is not really needed. In my case, I never use it on my machine. I turn key to the off position and the machine stop. There’s even ignition switch that when you turn them off are use for the kill switch.

      Some machine use a relay for the headlight. The relay is trigger by the ignition switch and turn on the light. The reason they do that is because some ignition switch are not rated for higher current. By putting a relay, they use a small current to trigger it and the relay power the light at higher current.

      Don’t know where you can find the plan for the Kandi 150. Don’t even know if it exist.

      If the engine do not turn over when you turn the key to the start position. Check if you have a bad solenoid or starter. You can turn the key to the accessories position. After, there’s 2 bolts on top of the solenoid. If you put a screw driver across the 2 bolts, it should engage the starter. Be careful and use protective gear required. If there’s nothing, it might be a bad starter. You can take it out and test the starter on it’s own. The case of the starter is ground and the red wire is positive.

      The most common problem with those machine are bad ground. Check all your ground, it might be as simple as that. If you have a bad ground, certain components will not work properly.

  5. I have a gy6 150cc Rocketa scooter and I wired it following your diagram and I can get it to turn over and it sounds like its gonna run but then stops and just turns over. It loses spark and I don’t understand why. I know it loses spark because I’ve put sparkplug on metal and can see it stop sparking

    • Sound like the CDI is only power when you are at the start position on your ignition switch. If you check the video again, when I do the ignition switch, there’s +12 volts coming in, one wire is accessories / CDI and the last wire goes to the starter solenoid. You only have power on the starter solenoid when the ignition switch is at the start position. If you put the CDI on this wire, it will power the CDI ONLY when you are at the start position. Soon you release the ignition switch to the accessories / CDI position, the CDI don’t have power on it anymore and the CDI stop sending the signal. Take the CDI power and put it on the ignition switch when you are on the first click / accessories of the switch. You always want power to the CDI.

  6. I got a carter bros GTR 250. Is it the same wiring diagram? I tried to change the key switch, I found the positive and the ground . If I join the two wires green and green/white, there was a spark. But as I joined the other three wires , for the break lights, headlights,and probably kill switch, suddenly , no more spark. I probably messed up the kill switch, or fused,? I need your advice.

    • It’s not the same wiring diagram. Some components are the same but some are not. There’s an electrical plan in the Carter GTR 250 manual, you should follow it. The key switch should not have a ground on it. It’s a 5 wires switch, 3 are the same as the 3 wires show in the video. The other 2 are use to connect the output + 12 volts from the regulator to the +12 volts of the machine. In other words, when you start the machine, those 2 connection give you more power to the machine.

      Check your fuses and change them if you have bad one. As for the rest, you need to follow the plan, it is hard to explain wire by wire. Make sure that what you do is right otherwise you might damage or break components. As you probably know, some of those parts are hard to find now.

  7. Thank you guys so much for this video it’s the only one I understand I don’t have a buggie but I custom built a scooter with a gy6 150 and the wire is all I have left I’m still working on it I have not got it to start yet I still don’t have spark and I’m not sure why. I’ll get there though I’m so much closer now thanks to this video any and all help is appreciated far more then you imagine have a good day

      • When I bought it it had a DC CDI so that’s the one I kept but for the life of me I can not figure out why I don’t have spark can you tell me the gap in the spark plug maybe that’s what’s wrong because step by step I fallow this video and I don’t have spark

        • The gap should be 0.7mm from what I see online. I never check the gap on my spark plug. Here some problems I did have before. Like you I check everything and have a weak spark. I changed the spark plug and it start. Spark plug are cheap. In this video, https://youtu.be/kFsyleMQXMc I do the testing around. Check if you have the same value. I also found out that after time, the flywheel goes bad. The magnet become weaker and do not make the contact work. Another one bad ground. The ground will give you continuity but if you check for 12 volts DC on a multimeter you have a lower value, mean something is wrong, usually ground …

  8. Hi. I have a Fang 200 GKA. Some times when i turn on any light or press the break every light and panel turns off. Not any cable loose. Some times y turn off and on and it works. Any clue?

    Thanks

    • I have similar problem before. My problem was the main positive cable coming out of the battery was bad. It look good but the connector didn’t connect properly anymore. Take a multimeter and check the voltage. You will see a drop in voltage where the problem is. Start with the battery and follow everything.

  9. I have a 2021 Trailmaster Challenger 200x. Ran great, but now when I press brake pedal to start, no power on odometer/fuel guage and it will not crank/turn over. I noticed on your video you had no brake pedal switch. I checked my 3 wire switch and kill switch; battery power 12.7 V at battery, 3 wire switch and kill switch power wire. Is brake pedal switch suspect (don’t know how to test it fully)? The brake pedal goes into master cylinder and a wire comes off the brake line to rear brake. Any insight would be great (and a wiring diagram). John 3:1-3

    • The brake pedal turn on the brake light and is also use to engage a relay. This relay need to be engage to power the solenoid and at it’s turn engage the starter. Check when you push the brake pedal is the brake light get brighter (like a car). If the brake light work, you can check the relay. There’s 2 wires that will power the relay and there’s 2 wire that will let the power go thru for the solenoid. If you know enough in electricity, you can bypass the relay to make test and find the problem.

      • Reposting as initial post did not appear to stay on thread:

        The brake light does not work with key on…only speedometer/gauge light up and stay on until
        Brake pedal pressed. Accessories (horn, turn signal, headlights) also do not work at all ( 12V+ Coming on hot wires to key switch, kill switch and speedometer/gauge). Since the brake light does not work, does this still warrant testing this relay? Or do you suspect something different to try now?

        • Sorry for the delay, this post slip thru …

          I have similar problem before. In my case the +12 volts did have corrosion under the terminal. The way you talk you are missing a lots of power and i did have the same thing.

  10. Hello I have a helix 150cc go cart. I’ve changed the stator, relay, cdi completely everything to do with ignition. I CANNOT get a spark to save my life. It cranks fine I can smell the fuel just will not start…. any help would he greatly appreciated.

    • Check to make sure you have +12 volts. A common problem with those machine are bad ground. You can even use the proper size wire and bypass it directly to the ground you are testing. If the machine start, it mean the ground is bad.

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