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By Adrian Ciotinga
The title pretty much explains it all. When using the starter I can hear it spinning but not engaging the engine. The wheels also do not engage with the wheels when the clutch is out. The motor has compression if that helps.
I am new to engine work and repair and I bought this quad with the idea of fixing it up (not knowing the full extent of the damage). The previous owner said it ran but sat for a year (I don’t believe that for a second after opening it up) and had bought a few new plugs and a starter motor, none of which fixed the issue.
Any help would be greatly appreciated!
I have attached a few pics of what I think could be wrong.
Fixing up a 1998 King Quad 300. The rear brake was locked up, and the owner tried to force it free and snapped the axle.
I disconnected the brake cable, and tapped on the backing plate with a soft mallet to get the brake freed up. When I pulled off the brake drum a bunch of nasty rust water came out.
Once I had the axle out, I popped the boot off so I could see the inner u joint so I could phase/synchronize it with the outer. There was a flat steel disc floating around in the boot, looks like it used to be pressed into the end of the axle. Glad I got that out of there before it munched up the joint.
The book says the yokes should be aligned, I couldn't get mine aligned. They were always 7 degrees off from each other. A bit frustrating, maybe that's within the tolerance limits?
But I got it all back together and it runs great.
So I put a headlight wiring kit from LMC Truck on my '96 Cherokee that circumvents the normal wiring and runs the headlights directly off the battery by way of a relay. The kit runs the lights at 55/100 (low, hi) watts instead of the original 55/60. One reason I did this was because the light output was terrible, and the other was because for some unknown reason the headlights would shut off after being on hi for a bit. Never did this on low. I've had the new wiring kit on for a few years now and it seems to have solved the issue.
The problem I'm having now though is that this new harness is melting at one of the connections...
You can see only one of the wires is overheating while the other seems to be ok. I'm guessing the hot one is used by the high beams.
What could be causing this? Could it be related to why the high beams used to shut off before I replaced the wiring harness? A while back I asked about the shutting off issue on a number of Jeep boards but nobody had heard of this particular problem before.
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