I have an 2002 Warrior and everything has been fine on it. I was riding and then stopped. From that point on the electric start doesnt work.. I swapped batteries and everything was still dead. Not sure if it is the entire electric system because there are no bulbs in the lights at the moment. The quad will bump start and run fine though. Any ideas where to begin troubleshooting? e start button?, run switch bad?

 

well you have to start somewhere. But first, avoid bump starting that thing whenever possible, you'll tear up your starter clutch. Use a screwdriver, pliers, or a heavy gauge wire to jump across the large terminals on the solenoid, and that should start it.

Did you check the fuse yet?

Let me know if jumping the solenoid starts it or at least turns the the engine over, and we can go from there.

 

i have the same problem as well, if i jump the relay the quad starts fine but i have nothing from the swtich when i push the start button.

 

The next thing i'd check is that your starter button is sending voltage to the solenoid. Use a test light or voltmeter with one lead on ground, and the other on the small wire going into the solenoid. Push the stater button (with the key turned on, of course) and see if you get any power through the button and wiring.

 

Hey, I wanted to add my 10 cents from helping someone troubleshoot this before.


See if the start button works if you pull the clutch in, even if you aren't in gear. If that works then you got a problem related to your neutral switch or neutral relay.

The run/stop switch is directly connected to the CDI. If it failed it would also cut out spark.


On 2002-2004 models the starting circuit cut-off relay was moved into the CDI.
If the CDI is in "Safe to start" mode, the Blue/White wires on the solenoid should have +12V. The Red/White wire should ground out when you press the start button.

I have seen the newer CDIs fail where it caused the CDI to always think its in gear. The neutral light is turned on via the switch itself, not the CDI, so the light will work even if the relay in the CDI is bad. Unless you have a known good CDI to try, you will need to rule out every wire and switch related to the safety switches. If you find out the CDI is the problem you can override the safety by giving the solenoid +12v where the Blue/White wire went. You want it to only have power when the key is on. The Brown wire from the keyswitch has power when its turned on. Just remember, it won't stop you from starting in gear anymore.

 

it sounds like what i had wrong with my cdi, listen to rruser, i am the one that he helped. all i did was tap into the hot wire in the harness, and run the new wire (now with +12v) to the solenooid and hooked up to the solenoidwhere the blue/white was. it took a while for us (well mostly him) to troubleshoot but the remedy itself took 5 minutes. if you guys want i can take a picture of how and where i hooked the hot wire to. send me a private message with your email.