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Old November 14th, 2020, 06:48 PM   #1
Lachlanrobs
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Smile Mounting 250r engine on go kart

Hi all,

I’m currently in the process of trying to make a go kart powered by a 2008 250r motor I have found the wiring diagram online and am struggling to remove excess wiring that I do not require. I have seen another thread where somebody put and older model motor onto a go kart but I was unsure about the newer model. I will include the original wiring diagram and the diagram from the other thread. I’m basically trying to figure out whether I need to include diodes and how the new wiring harness is different from the old and what I will need to get my motor running.

Any help would be greatly greatly appreciated
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Old November 14th, 2020, 07:26 PM   #2
DannoXYZ
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MOTY - 2018, MOTM - Nov '17
Hi Lachlan and welcome to Ninjette!!!

To reduce wiring-harness, no need to consult wiring-harness. But at least connect everything and get motor running first. Then start at end with unwanted components to remove:

- headlights
- turn signals
- tail-light
- dash

Trace wiring from those components back to main harness. Go as far as next connector and cut off wiring there. Heatshrink some tubing over end to insulate and that's it. There's really not much weight-savings in trimming harness. I recently made bare-bones race-harness recently for my '08 race-bike and I'm thinking I saved 2-lbs max. I might be able to save additional 1-lb by going to aluminium 26-ga wires and remove all connectors in between with direct wiring between components.
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Old November 16th, 2020, 08:08 AM   #3
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Old December 15th, 2020, 10:49 PM   #4
Lachlanrobs
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Thanks dannoXYZ for the reply but the original wiring harness is in pieces and nothing is interconnected just the components with a couple wires hanging out. I didn’t want to use any original wiring because everything was a tangled mess and some things unneeded like the fuse box or missing.

I was hoping to get a wiring diagram with the required components to make the motor run. I didn’t want to start connecting things and try get the motor running in case I damaged it. In the photos attached the diagram for the older ninja engine doesn’t have any diodes but it has a resistor. If somebody who knows what the motor requires to run could edit the attached diagram or draw up a new one so I can then make the harness fit the go kart I would be so grateful
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Old December 16th, 2020, 10:06 PM   #5
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MOTY - 2018, MOTM - Nov '17
Use that 1st diagram with new-gen schematic to re-create this one:



Some of wiring colours have changed throughout generations. I recommend retaining starter-solenoid and activating it with start-button. Otherwise, trigging starter directly requires massive switch that can handle +50amps!
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Old December 16th, 2020, 10:47 PM   #6
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MOTY - 2018, MOTM - Nov '17
here's another diagram. Good that it re-uses starter-solenoid.

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Old December 16th, 2020, 10:48 PM   #7
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MOTY - 2018, MOTM - Nov '17
This one is actually best. It labels the wire-functions, not just their colours. I find lack of fuse on power-line going to coils disturbing... add a fuse there.

Also add momentary button on Y/R wire between ignition-switch and starter-solenoid as start-button.

And I'd get power for fan circuit directly from battery rather than off starter-solenoid.


Last futzed with by DannoXYZ; December 18th, 2020 at 01:58 PM.
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Old December 17th, 2020, 10:45 PM   #8
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MOTY - 2018, MOTM - Nov '17
one more thing not obvious is mounting point for ignition-coils should be grounded. It's part of secondary-windings and needs to be grounded to work.
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