Frank Angerano

Hey was that relay used it looks burnt up?? Those prongs should not look like that. I would not use that relay. It looks all wrong. The relay looks distorted and burnt up.

What I don’t understand here is I sent you a direct link to the original equipment manufacturer part and you got a different relay ? All you needed was that relay and some steak on connectors for it. I’m sure that relay will work but it’s not necessary and could be avoided.

Relay ? Can you possibly take a picture of the relay. Just like the one I sent you and post it?? Can’t see the first two

Here’s what you do. Hook all the wires up except for that green wire and turn the key on. That relay should click. You can hear and feel it. If so then you can touch the green wire to the red momentarily!! See what happens. If you get an arc or heavy spark when you do that take it right off. I just can’t be sure due to the wiring not matching but it’s a relay and they are pretty simple.

Brian you can’t just connect the wires if they don't match. You have to make sure it’s the right relay first of all. Where did you get it?????? What makes you think it’s the right relay? That last red wire that should be a green and white should match what you have on the bike. So please like I said snap a pic of the relay without the plug and post it. This way we can look at the relay and see that it matches. Then you can go from there. If it matches then I would say yes you can connect that red. I’m not just going to say yes or no to something that could possibly burn the entire harness. i have posted a pic of the relay and what it should look like without the plug in. Also please respond within this topic so we can keep a constant thread and follow up properly.

Wow TPI that was a good set up. I still have one of them engines from a trans am gta tucked away in the back of my garage on a dolly. But agreed, one stupid connector or plug can wreak havoc on a person!

Any luck ?

Sounds like a great time @Ajmboy it seemed like a very busy year for fireworks. My town literally looked like it had a heavy fog condition that’s how much smoke there was in the air. We had stuff going off everywhere! Bbq 🍗 for sure and plenty of bud light and Coronas for mamma and some good company. We are heading out Monday AM to the tropics for a while. Def post some pics when we get back. Well deserved vaca!

That’s a common problem with lots of connectors with these bikes. Most of the time it’s a simple fix but we (even myself) in the past have started pulling parts off. Now that’s one of the first things I look for and open up, clean and add dialectic grease and check for either a slipped out pin from the base of the clip or I’ve also found that wires break at the bottom of the connector but the vinyl insulation is still good. It’s usually very flimsy when you bend it. But that’s a great find and an easy fix! So the hard start, what’s your thoughts on the problem ? Have you checked the amperage while cranking ?

The new relay. Unplug it from the wired plug that came with it and face it at the camera so you see the prongs where the wires go. Snap a pic of that. It should look like the picture I’ve attached here. There’s a small square on the bottom of the plug and a larger one at the top. This way you know what way the wires go. Then all you do is connect your wires to each one of the new relay wires accordingly. The only thing I’m concerned with is why your wire colors don’t all match up. Where did you order the relay from ?

And does it move freely ? Linkage connected properly? Have you is inspected everything for proper operation?

Unplug the relay form the wires. Take a look at the pic I sent you of the relay itself. Face the relay that way and match the wires.

Post the pics of the new relay and the wires.

That could be a solenoid, a dirty plug or connection, switch contacts etc. Nothing burnt up though right ? Fuses were all good prior to the rectifier swap out ? Nothing happened to the bike? Got banged? Any service work done that could have resulted in a pinched wire ? Check along the neck of the bike on the front end where everything comes up to the controls. I would think you should also unplug, clean and add dialectic grease to the connections as well because this honestly could be something along those lines.

That sucks. Can’t trust the cheap ones. Same thing with the carburetors. Not good.

The gear indicator switch. It’s located on the transmission. Should have a Red wire with a white stripe. Also should be a purple wire and a green wire with a white stripe? See if you can locate them. This way we can confirm that it’s the correct diagram. That switch will lock you out of any starting capability if it’s faulty. You can jump wires to test it and see if you get dash lights. The red with white stripe and the green with white stripe look like it will bring the dash lights on if jumped together however you should only use a test light or ohms meter to jump these two Incase there’s and issue nothing will blow. Also the ignition switch. Test the plug for power and see if you have 12 volts at the ignition. If so what color wire has the power it should be the red wire.

Do you have the acceptable range shown in the manual for ohms on the pick up coil ? My guess is possibly the cdi sh** the bed when you used the cheap rectifier. Something caused a dead short. OEM always when it comes to the cdi and the rectifier. The stator you can get away with but I’ve never had any luck with the cheap parts like a cdi and or regulator/rectifier.

I never knew the belt had to go in one way or the other I know they put arrows on them as good practice to reinstall with wear in the same points. They show the belt number and arrow but the belt it’s self has no difference on direction as it’s constructed the same way no matter which way it goes on. I’ve pulled a belt out that had no marks on it. I’ve put them back in the opposite way and never noticed any slipping. Maybe I was just lucky. Anyway let’s hope it’s just a matter of an oil change.

Great pics! Enjoy the time off and ride safe!

So I’ve looked everywhere and it all comes up the same. The old number is superseded by the new number. The old part is roughly 0.7 mm or 3/4 of an inch in diameter and the new one is 26mm or 1.02 inches in diameter. Very strange. I was looking on eBay and found the part number for the oem one and it’s available if you want to take a chance? https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F333205331528

Sounds good. I’m going to go through the diagram today and see if I can point you in the right direction. I will also post the diagram here for you to use and go through.

Hey mark welcome to Quadcrazy. What’s the reverse shift process for that bike? I’ve never owned one but have seen a few out there. Is it a break lever pull in or a manual shift lever ? Maybe post some pics.

Exactly @davefrombc it has to be a safety switch issue. What do you mean you have power everywhere?

Hey mike, glad you posted your own topic. Easier to keep track of your problem this way. Ok so have you checked anything so far like the main fuses etc ? Did anything happen like battery issues etc? You want to look at the basic stuff first like all fuses including the main fuses that control the start and dash lights cycle. Then wiggle the ignition key, sometimes the ignition gets worn out and it’s in need of a new ignition. The contacts in the ignition get worn believe it or not and don’t make good contact. Wiggling the key or pushing in on the ignition switch in the on position works. Secondly is the neutral safety switches and the safety items that prevent a bike from starting. Are you handy with a tester because this will be one of those problems that will require some testing? I can get you a diagram for that bike once I know what your up against. You will also be able to download the manual yourself after 10 contributing posts on the forum. So if it were me I would start to check the fuses and main stuff first like mentioned above and let’s go from there. We also have a member that loves Polaris @JacobSlabach I’m sure he will have something to add here. Take a look at the things i mentioned first and see what you have going on. Let us know.

Wow ok ! That’s so strange. I am going to look at a few parts. Gone me a little bit.