I was just given a 90cc and 110cc quads that were not running. The 90 was too small for my son so I am using it for parts. the 110 is a hanma ,I believe made by sunl, Icant find a model # off of the frame anywhere, and the manual has no model info. in it. The 110 was stored by prev. owner w/ the handlebars wet so the handlebar switch (lights, killswitch, and starter switch) were all gummed up and the brake switch (rear brake only) had wires missing and both male terminals broke off. I took the brake switch from the 90 and wired it to 2 empty female bullet connectors I found in the wire cluster. I took the handlebar switch from the 90 also and put it on the 110, problem was the original 110 switch had a single harness where the switch on the 90 had 2 harnesses. I tried to splice one wire at a time but still could not get engine to turn over. now in frustration I cut the harness off and lost my wire diagram I drew. it is a 4 pin cdi, CAN SOMEONE PLEASE HELP!

 

Open up the switch and trace your wires. Then go back and trace your wires from the starter silonoid to the connector and that should easily get you started

 

So do the starter button wires go to the solenoid ground and power wires? right now the solenoid wires are run to the ignition switch and ground.

 

they should run to the ignition switch then over to the starter button. On mine the solenoid went i could only start it by jumping the terminals on the solenoid. Went and got a 30 amp push button switch and wired it to each side of the solenoid. works great

 

Thanks a lot. I'm going to try that

 

I attached a push button to the solenoid terminals and lo and behold she fired up and ran good.I unhooked the remote starter and tether kill switch and all three switches on the handlebar switch. the quad ran well ,I showed my son and he got all excited. Then i got into trying to figure out how to power up the lights but had no luck because all of a sudden it blew the 10 amp fuse off the battery. I then ran a jumper wire across the fuse connectors just to try to diagnose but the black wire off the ignition switch started melting, any body have any clue why? I am stumped.

 

almost sounds like you have something wired backwards. black should be ground with no power on it. Their should be a red wire coming off the battery going to the key. You should be able to probe the out comming wires from the ignition and find out what one was live with key on. then just trace backwards from the lights and find out where they connect.. Might be easier to cut off the wrap on the wire bundles to trace them.. I found it easier to take 20 min and pull the body off so you can se everything without standing on your head.

 

10 amp fuse is too big. most generally, 7 amp is the biggest you need or you'll burn wires. especially those that are grounding out and melting due to a hole in the wire jacket insulation, a broken wire internally, or a grounded wire circuit.

 

Thank you for the help Zrock and jaster. I couldn't' figure out what caused the overheated wiring but I rewired the entire bike, got rid of the kill switches so now the atv just turns off with the ignition switch and it runs great. What a headache getting to this point though. Thanks again