I bought the bike, and the owner told me it needed a battery and a solenoid. He was right No DOUBT. He had been running the atv without a battery at all for quite some time, which I know can damage things, but I still took the risk. The solenoid was only half there, looked as they broke one of the studs off and said screw it. Since there was no battery, there was no positive cable. On my rebuild, I replaced all of it. Fresh brand new battery, fully charged, brand new positive cable, brand new solenoid, and all wire connectors. Put it all back together, and rolled it outside.
Turn the key on for the first time since my rebuild so I’m checking all the lighting and such to see that it works. Headlights, dashlights, taillights all work fine. the 4X4 light on the demand button on right side of handlebars works. So Im getting power everywhere. I hit the start button and hear a big CLICK on the solenoid. Thats all it does everytime the start button is pushed. Just Click. Starter does nothing.
So i get out a tester and start testing wiring to make sure im carrying power everywhere, And I am. Im getting power from one end of the wires and cables (at battery and solenoid) all the way to the other end. I tested all wires. Its even showing I am getting power to the starter when the start button is pushed.
Next I pull the starter. Well when I took the pull start case off to get to the other two bolts for the starter, a bigg rush of gas and oil come out. Crank seals bad. So I replace those, clean everything all up with contact cleaner, and then I start to look at the starter. Its full of gas and oil. So I first take some jumper cables and hook to the truck battery and try to roll the starter that way. Does Not Work. Tore the starter apart and cleaned it with contact cleaner, let it dry and put it back together. Tried the truck battery trick again and BAM it works. Starter is rolling. So im thinking Im in good shape.
Put it all back together, and still…. CLICK. At this point I Sliced open the little rubber pouch just up from the solenoid and checked the fuse block and its ok.
IM STUMPED. I HAVE POWER EVERYWHERE FOR LIGHTS, THE IGNITION SYSTEM AND ALL HANDLEBAR CONTROL BUTTONS WORK. YOU CAN CRANK START IT AND RUN THE BIKE ALL DAY LONG. IS IT POSSIBLE I HAVE A BAD SOLENOID, OR SHOULD I REPLACE THE STARTER ANYWAYS, OR IS THERE SOMETHING ELSE I AM MISSING? ANY HELP IS GREATLY APPRECIATED.
