Tim-ANC

Do you get 12 volts going in to the starter button on the white black wire? If not check power into those switches up stream. If so, check power out with the start button depressed.

LT80 is right. Something with the start sequence circuitry that powers the relay to close. The one I used to own had a switch on the parking brake. If the brake was off, it broke the circuit to the relay. You have something like that? Do you have a wire diagram for it?

Says file not found on my BlackBerry. Out riding so not near a computer. Try searching the internet in general for a free download. Or PM Oxidized black.

Download the OEM service manual for the 1999 KQ model form this forum. It has cable and tube routing diagrams. Much of it will be the same as yours.

Fuel pump should be on the upper left frame fwd of the handle bars. It is the vacuum that operates the pump. You might not have the fuel tank valve port on your carb. If your tank valve is the simple on, off, res, type, you don’t need this. If it is the on, pri, res, type, then there is a vacuum port on the back side of it. Vacuum from the carb opens this type valve to allow fuel to flow to the pump. If you have the simple valve with a carb that has the fuel valve port, plug the carb port. It is not needed. Do you have a manual for this machine?

EBay is where I find most my parts for these old rigs. Bike bandit is my next source for new. If you go with BB, please go to the website in my signature and link into them from there. I get a small commission from them pointing people their way.

1987 Suzuki LT230E Quad Runner Parts, 1987 Suzuki LT230E Quad Runner OEM Parts - BikeBandit.com From a 1987. Neutral Switch. Item 49.

Looks like a reverse or neutral position switch. What year is it?

Glad to help. These have a tappet shim valve adjustment which I've never dealt with. Like you say, you like to learn. Download the service manual from the forum. Knowledge is power.

What kind of noise is it making? Is it at a Suzuki dealer? Most us around here would tear into it ourselves, but it doesnt sound like you want to bother with that. 142 PSI is the standard compression per the manual. 130 isnt very bad. Might be solved by a valve adjustment. Ask them that. Do they have the head cover off. I dont know how one can know it needs a new cam shaft and bearings if not.

First, I would get a second opinion. What did you pay for it?

Good to hear. So it was full of gunk and shorting out. You can buy rebuild kits for these cheaply. Should be fine for your outing. Good hunting and do post pics. The website in my signature has some interesting hunting stuff.

I dont thing you did any thing too it. Looks like an old burnt out starter to me.

Ouch, that doesnt look healthy. Does it smell burnt?

Caribou, central Alaska. Day 3. Decided to take a cow instead of leaving empty handed.

There are no gears, CVT drive. Plus it's a centrifugal clutch.

Impressive. Pulling the left crank case cover in frame is a chore and delicate process. I like your theory about the eccentric rotation on the gear.

Direct jump from a charged battery is best. Chargers limit amperage to deliver a trickle feed. Better to use the components the system was designed for.

Is the pull start broken or was it not equipped with the option? Yes, can be frustrating. Be methodical. If your starter does check good by battery jump, then the relay is the next suspect. After that, wiring.

Find the vin number and use on online decoder to figure out what it is. Usually stamped on a frame strut.

Best way to check the starter is to jump it straight from a charged battery. By what you described so far it does seem like a bad starter. There are rebuild gets for them. How does the pull start work?

You're on the right track. Seems like that one way clutch bearing gave out. Our maybe a piece of debris in it. Good news the starter gear shaft did not break anything in the case. Did you pull the crank case cover with engine in frame?

Yes the extra hoses are for venting. Should be two coming from the top rear, one on the left, one on the right.

Good luck and let us know. Just back from hunting myself. Need to get you ready.

The rotor should only turn one way and not the other. There is a one way bearing behind this. I hope that is ok. Otherwise you have to pull the rotor and need a special tool to pull that big nut.