ignition/ electrical

[steve shugart]

Hi everybody, need a little help with my 98' King Quad LT-F4WDX. Finally had to replace battery after 4 yrs, good for a battery I think, anyway installed new battery, turned ign switch,press starter switch and heard 1 click, no start. checked main fuse, ok. So the dreaded chapter 14,removal of fenderbody was performed. Then proceeded to run tests found out the starter relayfrom the positive side to the starterfeed side had no continuity, infinity. Ordered new relay, received and installed today turn on ign got a neutral light pushed starter button ,one click and now nothing. I had checked the neutral relay earlier and it showed good so I put it back in. Any ideas fellas? any thing will be appreciated, maybe I have to pull the starter and try field jumping it? I don't get the 1 click and then nothing, could the new relay be faulty? Before installing i performed the continuity tests recommended and it seemed fine🤔

[Mech]

A real common problem with those is the starter brushes. They wear out and they get stuck sometimes/often.

The starter relay has two windings to operate the plunger that closes the contacts. One set of windings earths internally in the relay, and the other set of windings earth through the starter. If the starter brushes are not making good contact the starter relay doesn't get enough power through both sets of windings to pull the plunger and close the contacts. Then you get a click.

I'd use a jumper lead straight to the starter's terminal, or, now you have the body off, straight to the starter lead going to the starter. Put another jumper to an earth and the starter motor should spin. If it doesn't spin, or if it struggles to turn, then it needs pulling out and stripping and a new set of brushes. Easy job. The new brushes come with a new mounting plate and springs and all ready to slip in.