I am going to either borrow or buy one tomorrow. Yes when I run a wire across the relay posts it churns over very slowly. I am e-mailing a bud to see if we can look into to tomorrow. Thanks again Manaic.

 

1) if you used anything less than a very short 14 guage wire, it isn't a valid test (I had suggested a screwdriver or automotive jumper cable) With too small a wire gauge, drop across the wire itself will cause the slow cranking, and we're trying to determine where the source of drop is occuring, not trying to add a new source of drop.

2) Measuring the voltages at several points, while attempting to crank, will tell where the problem is immediatlely. If you can get some alligator clip wires, so you can clip the meter leads to several places, and then have your hands free to exercise the starter button, short with a screwdriver, etc. it will be a lot easier.

Measure and write down these measurements with Black lead - Battery negative and crank no more than 2 or 3 seconds for each of these measurements

Red lead - Battery positive, Crank with starter button

Same meter lead placement, crank by shorting across large relay terminals with a screwdriver or jumper cable or a 2" at least 14 gauge wire.

Red lead to the battery positive connection to the relay. Crank with button. Then crank by shorting relay. (write down measurement of both)

Red lead on the relay lug whose cable leads to the starter. Crank with button. Crank by shorting. Write down both measurements.

Red lead - starter motor cable lug - crank with button. Same but crank by shorting relay. Write down both

Move black lead to the starter lug red lead to the battery positive. Crank by button. Then crank by shorting (write both)

Move black lead to the motor case... somewhere shiny and clean near the starter

Red lead to the battery positive. Crank by button. Crank by shorting (write both)

Red lead to the starter cable lug. Crank by button. Crank by shorting (write both)

With these measurements, we can tell exactly where the voltage drop is occurring.

If the first measurement (both leads on the battery) is below 9 or 10 volts when cranking, Its the battery, no doubt.

 

Maniac if you ever come visit NYC come look me up... I will buy you a beer and show you around. I am very appriciative of your efffort in helping me. I will print those directions and see if I can get this going. Thanks again!!

 

Okay so it's been a while.. been busy but I managed to squeeze some time into this. Well I broke down by getting a new starter. I got it in the mail and immediately I pull out the old one. The old starter teeth/gear did not move freely. Almost felt seized compared to the new one. I was certain it was the starter at this point. Pop it in... NO GO. So I replace the starter cable.. same thing.. buzzing. I tried connecting the posts again from the relay does not turnover whatsoever. I did rebuild this thing. I had a leaky base gasket so I had to replace them all. After the rebuild it ran great. Then I powerwashed it (I think) to get all the muck out and still doesn't fire. Again two weeks ago I jumped it off a car... rand like a raped ape. Once it died.. it would not turn over.

 

If it starts easily when jumping but not when on it's own, and if you had charged your quad's battery well prior to trying, it sure sounds like the battery to me.

You may have internal charging issues also, but lets get the start working before tackling other issues. CHARGE your battery for a LONG time. See if it will start the bike through normal means.

 

What I last did was pull the starter out.. when I hit the button it moved a 1/4" rotation and then that was it.. so to me there is nothing in the motor internally binding the starter. I will let it charge for a while..

 

Are you talking about the old or the new starter (turning 1/4 turn)?

 

Yes new starter... 1/4" turn when I hit the start button. I noticed it sparked a few times too.

 

When it only turns 1/4 turn, is there still 12V at the starter's terminal, and the starter is well grounded? If so, then sumpins wrong with the starter. If 12V goes away, then it's likely the relay. Is the relay still buzzing when you do this? If so then you still have battery or cabling problems.

Gotta sort this out, or you'll never find what's really wrong.

 

Yes still buzzing. I didn't test with a volt meter... but going to a buds house on Sun to look into it extensively. Printed out the advice you have given me before and going to run that routine to try to isolate the problem.