my 02 s-man 400 only starts with the pull start. the motor turns over with the key but will not start. I removed the starter and cleaned it out, put it back together, tried it, still nothing. But it only takes one pull to get it going, fakes me frustrated that the key wont start it, any ideas HELP!!!

 

Is it just the starter motor that is turning with the key? or is the whole crankshaft being turned over when you hit the starter.

 

does the battery have enough voltage to start it. sholud be at least 12.5 volt. or is the starter turning but not engaging the flywheel?

 

the starter is turning over the motor and i do have enough voltage (usually after trying to start it with the key it runs down the battery so i put the charger on it, still wont start). would the solenoid have something to do with it? how would i test it? open to any other suggestions!!

 

To be honest I'd start with a new battery. I was in your position - my starter would work with the battery, most of the times on the first start but almost always on the second. Then came the charging and jumping the battery until it wouldn't turn the starter at all. Keep in mind too that the battery always read about 12.5 volts or so (even at the end) but it got to the point it couldn't take a load (such as starting). I put a new battery in and it is a night and day difference. I barely touch the electric start and it fires right up!

Also, after re-reading your post, your battery should not be run down after trying to start your quad. With a new(er) battery, you would have a half-dozen or dozen tries starting before the battery would be noticably weaker. Unfortunately, just because you can measure the voltage of the battery around 12.5 volts doesn't indicate at all it would pass a load test (try taking it to an auto parts or motorcycle store to do a load test).

 

i bought a new battery for it about 6 months ago (thats when the problem occured), it still did'nt help the situation. i might have to break down and get the starter checked or replaced. still, i would like to know if the solenoid has something to do with the problem, might just have to go out and get a new one.

 

the solnoide has nothing to do w/ it as long as when you turn the key and the starter starts to work then the sol. is working correctly. alot of the newer bikes have to maintain at least 12.5 volts while tring to start(as the book says) but if you put a new battery in 6 months ago and its gunk already then there is another issue. 1st is it the right battery for the wheeler? 2nd did you check to see what the voltage is while its running to make sure the charging system is working. 3rd is there a short some where running the battery down. 4th is the starter dragging, meaning does it seem to turn over hard even w/ a fully charged batttery?