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96 Big Bear 350 2 x 4 starter wont engage

mailman1

By mailman1
in Yamaha ATV Forum

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mailman1 Apprentice

mailman1

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I have a 96 Big Bear 350 2 x 4 and I noticed last fall that when I went to start it that the starter would not engage when I pushed the starter button. This spring I charged the battery to make sure that it wasn't the problem but still wouldn't start. I get a buzzing sound from the solenoid when I push the starter button but no sound from the starter at all.  I took the batt. cables loose and cleaned them on the starter and both solenoid posts still nothing. I can start it by pulling the starter rope with the 1st or 2nd pull no problem.  About 10 years ago or so I had the starter armature turned down as the shop said it was getting worn some maybe it is getting to that point again. Anyone have any ideas feel free to jump in.

Ted Craig Apprentice

Ted Craig

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Mine was doing the same thing. I took the starter apart and cleaned it, i also analyzed the brushes, i got 15-20 starts out of it, I'm waiting on a rebuild. Dc motors wear out the brushes, so it could just be that. They make a rebuild (replacement brushes) for my 350, but if the brushes are not worn down, it could be something else. 

Also, you can use jumper cables on the starter itself to see if it is the culprit. 

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Frank Angerano Grand Master

Frank Angerano

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The relay wont buzz when you jump the lugs.  The reason for jumping the lugs was to see if the starter works in the engine cranks. If the engine did crank than the starter is fine and most likely the solenoid is what needs to be replaced. If the starter did not crank then you obviously have a problem with the starter and either put a rebuild kit or a new starter.   So did the engine turn over when you jumped the two lugs on the relay ? 

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mailman1 Apprentice

mailman1

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When you mentioned jumping the lugs I used a jumper wire between the two lugs but I did not use a pliers or a screwdriver between the lugs which might have something to do with it not trying to start.  But to answer your question No the starter or the solenoid didn't make a sound, but the clips on the jumper wire began to get warm when I would push on the starter button.  If a person takes the starter out can you test it with a pair of jumper cables and a battery with one clamp on the frame of the starter for a ground and the other clamp on the batt. post?

mailman1 Apprentice

mailman1

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OK to continue, I jumped the solenoid lugs with a screwdriver and nothing at all and if I try to start it with the starter switch all solenoid will do is buzz.  So then I took the starter off the machine and hooked up the jumper cables to a battery and to the starter and the starter will spin like mad so replaced the starter in the machine and tried it again but no luck.  Would this mean that the solenoid is probably bad?

Frank Angerano Grand Master

Frank Angerano

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No. Bottom line is this, if you jump the lugs on the solenoid the starter should spin! Unless there is a problem with the big wire going to the starter (which i doubt) then it should spin. You can take a jumper wire and go from the positive terminal on the battery and touch the lug on the starter itself to see if she spins.  If not then there is a bigger problem within the engine. But one step at a time.  Report back please. 

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mailman1 Apprentice

mailman1

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I went and hooked the jumper cable to the starter post and it started right off then I took the long starter cable loose from the solenoid and hooked the jumper from the starter post to the solenoid end of the cable and it started so then I took the battery out and checked the cells and found one cell completely dead with the others about half charged and this is after I had charged the battery the end of this week.I don't know if you can check a small battery with a load test but that is my next move. Advise if I'm on track.  Thanks    Oh yes and I should say I got the battery just last summer but that doesn't mean it can't still go bad.

Edited by mailman1
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Ajmboy Grand Master

Ajmboy

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1 hour ago, mailman1 said:

I went and hooked the jumper cable to the starter post and it started right off then I took the long starter cable loose from the solenoid and hooked the jumper from the starter post to the solenoid end of the cable and it started so then I took the battery out and checked the cells and found one cell completely dead with the others about half charged and this is after I had charged the battery the end of this week.I don't know if you can check a small battery with a load test but that is my next move. Advise if I'm on track.  Thanks    Oh yes and I should say I got the battery just last summer but that doesn't mean it can't still go bad.

Sounds like your starter is good. I would check power from the solenoid back to the battery. Jumping the solenoid should cause the starter to spin, but its not..correct? So my thought would be that you have no power at the post not connect to the starter wire for some reason.

Ted Craig Apprentice

Ted Craig

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On a side note, i replaced the brushes on my starter, they were $10 off eBay and it worked. The symptoms of the starter was it was going slow, or not at all unless you tapped it. IF....you take your STARTER....apart, put a line down the side. I haven't taken motor theory class yet but, it was reverse polarity twice after i put it together, i guess i had the magnets in the wrong spot.

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mailman1 Apprentice

mailman1

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Well I think we've found the problem. I took the battery in this morning and had it load tested and found out there was in fact 1 dead cell and the rest were low.  Only tested 9 V instead of twelve so got a new battery and came home and put it on the trickle charger for a while.  But then I hooked the starter cable back up to the solenoid and pos. cable to the battery end of the solenoid cable hit the starter button and it fired off right away using a spare shop battery.  Come to find out it was the battery all along but I didn't suspect it as much as I had just gotten it this last summer.  Anyway thank for all the help and ideas as a person learns what else to look for when something goes wrong.

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