Hi everyone and thank you in advance for time and assistance!!!

I have and 1987 LT230E (H). I have replaced the Battery, the negative ground wire the start button/lights switch on left handelbar, starter relay(2 of them) and fuse with all brand new parts. I also replaced the wire harness with a newer one but not brand new. The only thing I haven't rplaced is the actual key start but seems to be working fine.

When I try to start the quad using the start button....nothing happens. If I disconnect the starter wire from the starter relay and tap the battery it will start right up....a few sparks though. Once I reconnect to the relay again nothing. I have the manual and it really doesn't explain it well and the wiring diagram is difficult to understand also. What am I missing here.....any ideas ?

Thanks!! [img]i/expressions/face-icon-small-smile.gif[/img]

 

Not much help here, your just going to have to track it down. Places to look are where the wires could have rubbed against the frame, if your blowing fuses look closely for this. Also look hard at all switches. Including the on/off switch on the left handlebar.

Now you see why some places charge more for electrical problems.

Good Luck,
Rob

 

I have gone through just about all the electrical probs on a 230e you can think of. Please explain what you have done a little more so I can get a better understanding of what is happening. Do your lights and everything work? What sparks when you disconnect the relay?

 

Are you ready......

I got this quad with half a wiring harness, white indoor house wire and a 72 Ford relay starter. I tore it down to nothing and started from scratch. I replaced the wiring harness with a complete and newer one, so I am not sure if this is the problem to begin with. I put in a brand new battery with a full charge, a brand new negative ground/frame wire, a brand new starter button assembly and fuses.

Ok, so when I have the quad connected as stated in the manual, I get nothing from the actual start button on the leftside handlebar. If I use the pull start it will fire right up. If I disconnect the wire that comes off of the starter and attaches to the left side of the relay starter then touch it to the positive post on the battery, the starter will fire and start the quad. I just ordered new bulbs so I'm not sure about the lights.
I thought that since things seem to end at the relay starter that it may have been bad but since I have two brand new ones I don't think that was the problem.

I can tell you this I just took a look at the neutral switch near the reverse lever on the left side of the quad and it appears to be messy. Someone said that if the quad thinks it's in a gear other than neutral it may not work or if the parking brake isn't engaged the button may not work as a safety check?

The actual key switch looks like it was glued together. The key will not come out but does turn freely to all postions and will cut the engine if turned all the way up, so I doubt that it is the problem even though it looks a little messy.

You asked about sparks......whenever I tap the battery with the starter wire it will spark until it starts and I take the end of the post. I'm missing something here................lend me your expertise.............please

:-)

 

I think you have it solved. Disconnect the neutral saftey switch and try it with the wires closed, and open. Not sure which would work. I would assume closed.

 

Hey there,

I just got a bunch of parts including new bulbs. I put them in and they work fine. When I turn the key to lights the come right on, and the high and low slide works great as well on the leftside handlebar.

The only thing that I can think of is that it's this messy neutral switch by the reverse lever. The lights in the key box don't work so I'm thinking that the CDI is telling the quad it's unsafe to start because the quad is not in neutral. I'm gonna try to fine one and see if that finally does it.

Thanks for following up!

 

I may have a spare one laying around. I'd run a VOM meter on it. If I get a minute I'll post the diagram tonight, if not in the morning.

 

I tried to take a picture, but all you get is flash. It looks like they need to be a closed circuit. There is also a neutral relay under the seat.