Some wiring??? On my vc clone swap

Younggun

So I now have the clone mounted in my 2002 workhorse with the comet clutch installed and have a few questions for those of you who have done this swap. How much of my factory wiring actually gets reused and what can I start eliminating? I would like to simplify this cart by getting rid of all the necessary components now that the clone is in and ready. Any input or advice would be appreciated

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sho305

Depends on the ignition you had in the stock cart, did it power the ignition with 12v from the pedal (assuming you are keeping the pedal start and gen?) or did it ground the engine to kill it like a lawnmower? If it grounded the stock engine you can use all of it just like stock the clone is a magneto ignition. If like my yamaha and 12v powered, you get a bosch relay (5 pin) and harness if you want, then wire it to kill the engine when off. Leave the gen wiring on, use the hot from the coil to power the relay and un-kill the engine when powered up. Remove other ignition components, though the yamaha I just unplugged them and taped up the plugs.

A magneto power ignition (self powered) will have the coil on the flywheel like a pushmower does, the clone does. It runs off magnet(s).

aladd6

All you need to do is connect the Bosch relay ( controlled by the pedal) to the kill switch wire on the clone. Do a search on here there are wiring diagrams here.

Younggun

Thanks for the help I'll try doing some more searches for the diagrams

sho305

Pin 30 and 87A are always connected until you energize the relay (to energize run 12v though 85 & 86 pins; you hook one to 12v from pedal the other to ground). So you connect the kill wire and ground to 30 and 87A to kill it (kill wire and ground on other pin) and it will run when you press pedal. Make sure you get a bosch 5 pin relay with pin 87a some only have 4 pins and will not work for this. Bosch relay are very common in automotive, many cars have a bank of them under the hood. They are $3 or so online.

Younggun

Thanks again for the help Sho305 i will try and pick one of those up today while i am out and about

bigjohn141

Can I ask a quick question since I will be install my 440 this weekend I hope. With this relay setup, will the magneto provide enough current to open the relay and allow the motor to start if your battery is dead and you try to start it by the rope? It's not a big deal if the answer is no but it would be a good thing to know.

sho305

Relay is powered off the battery when you use the stock generator. To pull start it all you have to do is unplug the relay, or the kill wire to the coil (or the ground wire it uses on the other side of relay). Never put power to a mag kill wire it can destroy them. You could put a switch on the kill wire or the ground wire to disable the 'kill' circuit if you wanted. I bought the harness for the relay and a tab mount relay, so I just pull the whole plug off the relay to disable if I need to pull start.....though I never had to do it yet.

Remember a relay has a powered side that runs it, then the other side that just switches something. They are not connected unless you make them. Note the kill side has to ground to the engine block in case your battery is not grounded to it, because not all carts ground the frame and engine together though the gen will be and is usually bolted to the block.

bigjohn141

Thanks for the info. I think I am going to wire the ezgo a little different since Geoff recommends killing the motor via low idle. I am going to wire the 12v for the relay to the key instead of the pedal switch so that way the key will act as a emergency kill just by turning it off if needed.

sho305

I had mine killing with the idle at nothing, but if your throttle sticks you will be in trouble. Anyway, it starts better with the idle set. Set it up how you like, just make sure you can kill it somehow if you ever have to.