I am starting to have problems starting my 05 Rubicon. Sometimes when I go to start it, I push the button and it does nothing but clicks once. It is coming from the selonoid, probably isn't spelled right. This is what I don't understand, if I pull the pull start out just a little, but don't start it, it will start with the button after I do that. Right before this started to happen, I washed the bike off. Something could have got wet and be causing a short but it did start a few times after I washed it off. Has anybody else experience this before or heard of this? I hope I explained it clearly enough.

 

Sounds like you got just enough moisture somewhere to create enough corrosion to break contact. Start with your battery cables. Disconnect them from the battery, clean all connection points,both battery and cables; with WD-40 and a terry cloth towel. Then disconnect the starter,solenoid, and battery ground wires, and clean them too. Many times people clean the 'hot side' of the battery/starter circuit and neglect the 'ground' side, when it's the ground side thats at fault.

To help protect against corrosion in normal conditions, spray all connections with WD-40 and let them dry, it will shield them from routine moisture. Auto parts stores sell a spray on battery cable insulation that dries to a hard coating, try that or dielectric grease for severe moisture conditions.

 

I don't know if the solenoid and the starter relay switch are the same, but the part I'm talking about is the starter relay switch according to the service manual.

 

My mechanic experience is with cars. To me, the starter relay has (small) wires running to it from the ignition (key) switch. It has (2) large battery cable type wires leading from it. One comes from the battery, the other goes to the starter.

The relay closes the circuit between the two cables when the ignition key is turned to Start. On the Rubicon the Start button does the same.

The solenoid is part of the starter. When current is applied to it, it kicks the pinion gear on the starter out to engage the flywheel and turn the engine over.

Now that I explained all this, with the key ON- Gas ON- Kill Switch to Run-jump the two big cables coming off the relay- Press the starter button-Does the quad start and run?. If it does, check the wires from the key switch with a volt meter for 12 volt DC current. If no voltage, clean connections, or replace key switch and retest.

If voltage IS present- with key off-remove the two big cables from the relay. have a friend turn the key on and press the starter button. With your volt meter set for 12 volts DC, check the output side(to starter) of the relay for voltage. If voltage is present, relay is fine, test the starter.

Test the starter by jumping a cable directly from the battery to the starter. If the starter turns over but won't engage the flywheel, the solenoid is bad. If the starter makes no noise at all, it's dead. Replace both as needed.

All this is tedious work, I know; but I'm sure it will take you less time to test it all than it did for me to write it here.

Check www.mrcycles.com for prices.

HTH Hefty

 

Does this make sense, if it clicks whenever I hit the button, pulling the pull start out enables it to be started with the button? Also, is the solenoid the same as the relay? And I could not find the relay on the microfiche. What is it located under?

Nevermind the last question, I found the relay, it was located under battery.

 

Angler

Honda even calls the solenoid different names between service manual and parts fiche.
The service manual calls it a starter relay and Parts calls it a magnetic switch.

Reguardless, If the starter relay clicks, it is most likely working.

Try this, locate the starter, You probably know where it is, when you are sitting on the ATV on the right side by your ankle is a gray engine cover just above the right footwell. Under the upper rear of the cover, near the right side body cover.

Turn on the key, depress the starter button and tap on the starter with a small hammer or cresent wrench while holding the starter button in the start position.

If the unit spins over you most likely have a starter brush hanging up and not making contact.

If it does not attempt to turn the engine over, take a test light and connect the clip to a metal part of the engine and touch the probe end to the battery cable where it connects to the starter motor (under a rubber cap on top of the starter motor). Turn the key on and push the starter button. The light should light up.

Let me know


----- Gimp -----

 

Do I need to remove the cover off the starter before I tap on it? I will let you know what I find out. If it is the starter, would it be better to rebuild it or just buy a new one?

 

I usually just pull the cover away a little, just enough to tap on it.

If it is the brushes, parts will run somewhere between 30 and 40 dollars plus labor to rebuild.

Check the price on that starter, Honda has some starters available that are about as cheap as having yours rebuilt. I can't remember off the top of my head if this Rubicon is one of them or not.

For me, they are easy to rebuild. Of coarse I have rebuilt tons of them.
If you end up removing the starter, be carefull that the battery cable mounting post on the starter does not spin with the nut when removing, if you are to have it rebuilt. There is a porcelain type insulator just inside the starter that needs to be reused if the starter is rebuilt. Use a wrench to hold the lower nut if needed to break the top nut loose. Also if you have it rebuilt, have them double check if the nose cone needle bearing has moisture in it. Seen a number of Rubicon starters that this bearing has went out from moisture. If that bearing is bad the nose cone has to be replaced. Then the cost of a new starter comes into play.

Like I say, let me know. I have my laptop in the garage and am working on my Sprint Car, so I should be off and on the net tonight.

----- Gimp -----

 

Well I hit the starter with my hand with the button pushed and it started so I guess that means that the brushes are hanging up. Would I be able to rebuild the starter myself or do you have special tools to do it?

 

Yes, you could rebuild it yourself.
If you decide to do it, I can give you some pointers. Or walk you through it.



----- Gimpster -----