Hi, We have replaced the starter (it was bad, wouldn't even turn by hand), solinoid, Took battery back to supplier and had it verified the battery is charged and in goog condition (New) When we try to start we here a click coming from in side this covered switch. There is a red wire coming from the soilnoid going to this and when we disconect the click stops, maybe a relay? The lights go off when we try to start. Like a dead short, any ideas?
Thanks,

 

Small red wire leading to the solenoid (magnetic switch as it's called) is from the ignition switch and powers up when the switch is turned on. It triggers the solenoid to transfer power to the starter. If the solenoid just clicks, then just replace it. Common problem for these to go out. Plus you can also just double check that no power is going to the starter with a test light or simply jump the the battery and starter wire on the solenoid to see if the starter works properly. IF you're talking about clicking coming from the sealed pouch (thermal circuit breaker),then split the pouch and check if the connections are corroded and power is going through both sides. Could be this 20 amp circuit breaker needs replacement. You can find it at any auto store for about 5 bucks. OPT

 

We change the solinoid twice now. We just noticed the new strater is getting hot. We did take off the pull start (It was hard to pull) also and cleaned and reinstalled. Seems better but still hard to pull. ATV starts up. Is it possible the gear assembly in front of starter that engages into is bad. (Stuck) on flywheel?
Confused///

 

We tried to jump start also and same thing is happening.

 

If you didn't replace the starter gear shaft (bendix) or clean it and grease it, then it could be hanging up on the flywheel and causing the problem. I always just thought it was best to replace the bendix and starter at the same time and be done with it!. They are cheap enough at DB electric to buy both. OPT

 

Yep your right should have bought the bendix. (gear) Took pull cover off and the gear is all rusted inside, Tried new starter and spins fine with gear off. Ordred new part tonight. Thanks for the help.