1993 KLF 400 "click"

[walleye]

My machine won't start!! It will "click" when I press the start button, OK, charge the battery! Full charge it still "clicked". OK, load test the battery-failed, buy new battery. Installed new battery--"click":aargh: Checked a couple of fuses-good. Look at wiring diagram and the click I hear seems to be the relay. I "assume" the relay is good since it clicks but then again it could be closing fine but not sending the required voltage to starter. Where to from here. I use this beast to haul a trailer for carrying wood for the coming winter. Any and all advice will be appreciated since I live in a rural area and don't want to trailer the machine to the city.

[hangingon]

It leaves me to think you may have a bad starter solenoid or starter since you have a new battery. check your cables also. I take it you don't have a pullstart or kick start and the quad is automatic. A bad soleniod or starter will click as well.

[pete59edsel]

^^^^^^

Agree. the click gives it away plus the fact you have a new battery!!

[marioweldinginc]

If you can jump the starter solenoid with the "ol" screwdriver method.

[walleye]

Well I appreciate the replies, but I'm mechanically inept. Is the starter the cylindrical shaped thing bolted to the motor with a rubber dust cap and 1 heavy gauge black wire? Where do I find the solenoid? I'm not afraid of learning. Thanks.

[marioweldinginc]

Yes it is. Im not sure about you particular machine but follow that heavy gauge wire and the solenoid should be in that circuit. Or you can follow the positve battery cable

You will see a small round thing with two big and two small terminals. Take a big screwdriver and put them on the two big terminals. Its gunna spark so be prepared. It should start or attempt to start your quad if not then your starter is kaputz

Dont leave the screwdriver on the two terminals for more than 3 - 4 seconds

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Edited September 11, 2011 by marioweldinginc

[hangingon]

On kawasaki prairie it's under the seat. But like mario said trace your cables It may be easy to go from the battery. Your battery cables will go to the solenoid & from the soleniod to the starter If you go to remove the soleniod or starter from your quad make 100% sure you disconnect the battery first. If you do try to jump the soleniod with a screwdriver do not let the screwdrive touch the postive cable and any other metal of the quad just the soleniod terminals.

[walleye]

Well, I'm getting back to you folks. Found the solenoid, under the seat, buried in debris. Looks to me like I'm gonna have to remove the rack and take off the "skin" to get to it as there is lotsa stuff in the way. I can't see it from the underside as ther appears to be a flexible shroud covering everything. I doesn't look like it's too complicated to remove the plastic skin. I'll be in touch. THANKS

[walleye]

Well I got it out and a new one is on the way. $30.00

Should be here Wed.

[hangingon]

Did you make sure it is the solenoid or are you guessing it's the problem and trying a new one.

[marioweldinginc]

Lol

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[walleye]

Did you make sure it is the solenoid or are you guessing it's the problem and trying a new one.

Well I had NO way of trying to short across the wiring. This thing is buried under the seat surrounded in a shroud of plastic and is IMPOSSIBLE to see, you could feel it in there but not see it. On top of that the rubber dust boots on the terminal posts had a silicone sealant on them and I had a heck of a time getting that apart so I could remove the solenoid! I did get it off and opened the solenoid and found that the copper contacts were pretty much arced away from the years of use. The contacts are the actual terminal posts where the nuts tighten the + and - cables. So I learnt a little on this adventure.

[marioweldinginc]

Killing 2 birds with one stone ..it was burnt up anyway.

Let us know if it fixes it. If not we'll figure something out

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[hangingon]

I hope that it's your trouble mine is simple to get too and after looking at mine it would be tricky to jump it. My thought would be 2 screwdrivers touch the terminals with log screwdrivers and touch the screwdrivers togather.

[walleye]

Update.

The solenoid I rcv'd is not a one for one replacement!! Original one had a molex type plug on it plus the posts for the battery cables. New one has posts for battery cables (good), an onboard fuse (20A), and 4 spade lug type connectors. The spade lugs have a different resistance when ohmed out. I'm thinking I'll pick the 2 with the least resistance rather than the other ones that have a resistor pack built in--is this OK?? I'll have to do some splicing on the wiring after I cut the molex plug free.

One question I have 'tho, is the circuit made when I push the start switch on the left handlebar?? I guess I'll have to meter it out and see??