I welded a spot on the front end without disconnecting the + cable from battery.After that it turned over,but blew fuses so i went bigger amps.After that i cleaned out starter no burn areas.I looked at starter button no wires burnt ect.After i went to bigger amp it turned over but got very hot so i stopped. does someone knows why ? please help...

 

you have a powered wire going to ground. time to pull out the voltmeter/ohm meter and start checking the power wires and make sure they haven't "melted" and gone to ground. please put the lower amp fuse back in.

 

Removing the plus cable from the battery wouldn't have done anything to protect the electronics on your quad. When welding on the quad place the ground clamp as close as practical to the thing you're welding, and unplug everything that has semiconductors in it (semiconductors are diodes, transistors, microprocessors, etc.). This would include CDIs, regulators, speed sensors, fuel injection electronics, etc.

The problem is that welders can deliver a lot of volts and current at the same time. My stick welder can deliver 80 volts at 120 amps. If you are welding on frame part A, and the welder ground clamp is on frame part B way over on the other side of the quad, and these two grounds are connected to each other through bearings, chains, skinny little ground jumper wires, or other bad connections at 120 amps then huge voltage drops are developed between grounds on the quad during the welding operation. If one electronics module gets its ground from Part A, and another from Part B - and they are connected through signal wires - the parts can be destroyed. Unhooking the battery means nothing. Its already unhooked when you turn the ignition switch off anyway.

Unplugging all the electroincs modules will solve the problem, or making sure your ground clamp is on Part A while you're welding Part A will solve the problem too. But if you do both you're doublely protected.

Go back to the original fuse size. Then unplug your voltage regulator. Try and start your quad. Does the starter turn? Do you still blow fuses (I suspect not)? Does you quad start?