LT80 QUADSPORT non runner

[Dean Walton]

Hi guys and thanks for taking the time to read this... 

I've took my sons quad apart to tidy it up and replace the carb.

Replaced carb sprayed exhaust etc.. And when I reconnect the battery I get no starter?? 

I tried charging the battery and replacing it again to no avail.. On the battery ground wire there are two wires that seem to be pressed into the same connector. 

I have read about a reset button under the wheel arch but can't seem to get it to work. 

 

Here's a screenshot of the two wires that I think have been fused together circled on a diagram. 

 

Thanks in advance. 

Dean. 

 

 

[Frank Angerano]

Fused together? Can you post a picture of the actual wires ?

Nothing should be fused together unless there's a short someplace or the battery was connected wrong.  
There is sometimes a fuse  next to the start solenoid that could be blown. 
 

[Dean Walton]

By fused I mean two wires into one connection going to the ground terminal on the battery.. But I've never changed anything on the wiring harness myself I've just put back on what I took off?

I can get a pic tomorrow when I'm home. 

[Frank Angerano]

Ok I thought you meant melted or burnt up. 
 

It's most likely something simple that was overlooked on the reassemble process. 
Take a look for that fuse i told you about first and then go back over your work step by step. Im thinking a wire got pulled out of a connector someplace.  

Double check the kill switch and ignition as well. 

[Dean Walton]

Where is the fuse mate? 

I could only find 2 and they were both sound. 

 

How do I check the kills witch? I've replaced ignition but I've tried old one back in and it worked before but still nothing. 

[Frank Angerano]

There should be one by the battery.   There is a round small relay. Usually right next to it is a fuse. Take a few pics and post them, we will point it out if its there. On some of the smaller atvs it different. I haven't looked at the manual but it should be there. 

Have you located that fuse #3 on your diagram? And lastly some of those bikes had the emergency rip cord to shut it down in an emergency if you fall off the atv as well as a brake switch where you have to pull the brakes in to start. 

[Frank Angerano]

[Dean Walton]

1 hour ago, Frank Angerano said:

There should be one by the battery.   There is a round small relay. Usually right next to it is a fuse. Take a few pics and post them, we will point it out if its there. On some of the smaller atvs it different. I haven't looked at the manual but it should be there. 

Have you located that fuse #3 on your diagram? And lastly some of those bikes had the emergency rip cord to shut it down in an emergency if you fall off the atv as well as a brake switch where you have to pull the brakes in to start. 

It has the rip cord and the foot rake switch. I'll look when I get home tomorrow mate thanks for all your help. 

And yeah I've located fuse 3 it looks fine. 

[Frank Angerano]

No problem brother keep us posted.  

[Dean Walton]

Here's the pics guys. All wiring at the front seems to be OK.

[Dean Walton]

Edit...  Its the fuse everytime I replace it it blows. Any ideas lads??? 

[Frank Angerano]

Which fuse ?

[Dean Walton]

She's all back up and running there's a block with two fuses in... This fuse kept blowing the 7.5 fuse. 

 

Turns out there was a wet connection in the black thing so I cleaned and dried it and she fired up and is now running like a dream. 😁😁 Thanks boys. 

[Frank Angerano]

My man !!! Nice work. 
Stay in touch, Quadcrazy is not just about fixing and helping out but a cool place to share pics and lots more. 
Ride safe. 

[Dean Walton]

I will do mate. Thanks for all the help... Next work is to get the restrictor in the ktm65 and spray the exhaust ready for Xmas day.... My boys will be buzzing. 

I'll share pics soon. 😁

[Frank Angerano]

Cant wait. Have a great xmas i hope the boys love the bikes.