For about a year, my ATV would intermittently crank but not start. I discovered that quickly switching the kill switch back and forth repeatedly from ‘run’ to ‘kill’ would cause the engine to hit once or twice, and often it would eventually catch and start, after about 30 seconds. Also, whenever it would hit, it would only hit when i moved OFF of the ‘run’ position into the ‘kill’ position.

I disconnected the switch assembly, and ended up cutting the two wires free and then just tying them together. Same condition… engine cranks while they are tied together, but wont start… if i remove them and touch them back together while i am holding the start button, the engine will sometimes hit, and it only hits at the moment they are separated.

Disconnected the wiring harness and checked voltages.

Wiring Diagram

In that diagram, at the bottom left corner is a "Starter + Engine Stop switch" box. The kill switch is labelled "IG2" and is a Bl/W wire that runs up to the CDI unit. There appears to be a diode (?) on the line.

With the key in the on position, and the two wires from the kill switch tied together:

Measuring from G (green) to Bl/W (black/white) while the start button is NOT being pressed, i get 12.3 volts.

When i press the start button, the voltage immediately drops below 11 volts.

The service manual only has this to say about inspecting these connections:

Test ignition switch and engine stop switch: (Turn ignition switch to ON and the engine stop switch to RUN) – Bl/W to G – Battery voltage should register.

According to that, i should be seeing the battery voltage when the start button isn’t being pressed, which i am.

When the start button is pressed, the voltage shouldn’t drop like that should it? Does the fact that it only hits when the wires are separated point to anything? The wiring diagram shows what i believe to be a diode on the wire… could this have something to do with it?

Thanks for any help!!