My 03 Raptor burnt up a starter relay. Jumped the relay and if fired right up. Stole a relay out of my buddy's and it started. Pulled his relay out and put it back in his machine and it was shot. Pulled one out of a third machine and put it in his and his started fine. Didn't want to kill a third one before making sure there is not anything causing them to fry. Any idea's what would short out a relay? All connections are tight. All cable are good no cuts or frayes. Any idea's would be appreciated.

 

If it still clicks after it is burned up, then you burned the contact points. Some things to check are: Battery not providing enough voltage during cranking, starter pulling too many amps (starter going bad, or starter bearings)

If it will not click after it is burned up, then you burned the coil up. Some things to check would be: Too much voltage on the small wires on the relay during cranking (not sure how this would be possible on an ATV, but it will definately burn up the coil on a relay)

 

your battery is shot or u have a aftermarket cam or your decomp spring it broke.