Hello everyone, New on board here with a puzzling question,, Here I go, I have a 2003 Bayou 250 that was starting fine for the frist half of the day this past Sunday, I ran it out in the pasture and on the street then shut is down, came back out hit the start button
and click click click click and no start, Pulled the rope worked fine, so Im thinking ok dead battery (six months old) nope not the case
starts my buddies 300 just fine, Pull out the silinoid out test it on a battery works great, checked all the fuses even pulled out the starter ran it on another battery works great, checked the ignition realy working good, but it all back together hit the button and click click click. Ok now Im getting mad, I start the bike with the pull start fire's up and I pull a lead off the battery to make sure the alternator is working and yep bike still runs. Battery Voltage is 13.1 volts, Headlights bright with bike is not running, ok here is the kicker, the Neutral light is very dim. Somebody shoot me Any help would be great

Mike

 

What is the voltage at the battery when you hit the start button? At the solenoid in. At the solenoid out? At the starter? Is there a voltage drop along the way? (other than a tenth of a volt or two) Sounds like a bad connection somewhere. Did you try unplugging and replugging the connectors? There are a bunch of them behind the access panel at the rear of the front rack. Is the reverse light dim too when you put it into reverse? Gotta be a voltage drop somewhere or else a bad ground with a dim bulb. Sounds like a fun one...good luck.

 

Check the connection of the "black" 14-gauge ground wire that runs from the Starter/Relay to the left side of the engine case as you sit on the bike. It would be where slightly behind your left knee, below your left thigh. The engine surface may have either rust or paint that makes a poor connection to the black ground wire connector ring. Wire brush/sandpaper the area to remove rust/paint.

 

Hayashi,,, You da man, You know after all these years of doing machanic work
I ignored the golden rule "when suffering electrical problems allways check
the ground first.
Thank you guys for both your help,, The lug looked great from the outside
but when I took it off the whole underneath was corroded, cleaned
reattached and fired right up


Thanks again

Mike

 

I have this same prob with a 03 Bayou 250 and I have not yet had a chance to check if Hayashis suggestion is the solution. In fooling around with it I hooked up my voltmeter with the negative probe to the neg battery post and when I touch the frame on a shiny bare spot down by the left foot peg I get a reading of about 10.5 volts or so....this is with the key on - machine not running. Would this be the result of a corroded ground wire in the place suggested?