I recently acquired a 1986 Suzuki Quad 230 when my father passed away. It had been running well but when I went to start it yesterday the battery was totally dead. I was able to get it started by using the pull rope but the neutral indicator light was not lit up. When I switched the ignition switch to the headlights on position the neutral indicator light would light up. I removed the battery, started the bike, and put a DC voltmeter on the battery leads. With the ignition on but the lights off there was no voltage on the leads. With the ignition switch in the lights position there was 3.5 volts on the battery leads. Does anybody have any idea what is going on? Your help would be greatly appreciated.

 

Sounds like it could be stator or rectifier problems, on most quads, there is a seperate lighting coil,so that could be why you see some voltage with the lights on. I dont know the wires to check for stator function, you will have to talk to a shop or grab a Chiltons manual for that.

 

Did the lights come on when you turned them on?
With the battery out there is no resistent on the changing system so a zero reading would be correct I would think but with the switch set to lights there is resistent and it amounted to 3.5 volts of draw.....
These systems are designed to have a good battery in the loop so until you have that stop where you're at unless you want to spend some money on unnecessary parts. If there is a problem after you install a good battery then it's more then likely the rectifier and that ain't cheap. Let us know what you find out!