Sorry if this post runs long but I'll try to keep it reasonable.
I have a small Chinese unit that's about 10-12 years old - can't exactly recall the year, but the problem I have could be with any vehicle so I am posting here in the general forum. Anyway, for the first 8 or 9 years I never did anything other than standard maintenance (oil, chain, etc.) and this thing started every time and ran just fine. In those first 8 years or so, I replaced the battery once, at about 6 years. I don't use it for trail riding, just small jobs around the place so it never really gets beat but does run almost every day in the summer. I put it up every fall and take it back out in the spring and like I said, no issues. About 2-3 years ago the battery went again, after about a year, and then I went on a run of batteries in the next couple of years. They never seemed to last a season so, obviously, something is not right. Last year after another battery replacement I was still getting a no start and no lights but the battery had power. I did some very minimal testing (I have a multimeter but I am not real proficient) and I thought I had narrowed it down to the solenoid and/or the ignition switch. Being that they are inexpensive I replaced them both and it ran fine. I got back to it this spring and expected some issues but it started immediately and ran OK (some intermittent engine surging) for about a month and then the electrical issues started up again and here is where I really get confused. A week ago I drove it a bit and shut it down and about an hour later I got the no start, no click, no lights...nothing, so I figured that I killed another battery. I was getting 12.8 V at the battery posts and about 12.7 at the solenoid. I jumped the solenoid with a screwdriver and it immediately turned over. Got back in and started it with the key, drove it around and everything was fine. Two days ago, same thing, drove it for a bit, shut it off and when I tried to restart it, about an hour later...nothing. I tried the headlights and they came on so I tried to jump the solenoid again. There was one very small clink and then nothing. No lights, no start, nothing. There is still 12.7 V at the battery and 12.6 or 7 at the solenoid but it will not jump start (crossing a screwdriver at the two poles of the solenoid). I have 12.6 V at my ignition switch and the same at the utility plug, but nothing at the headlight switch - which I really can't figure out.
I am not sure where to check but I would have expected since I have juice at the solenoid I should be able to jump it (the solenoid), or at least get sparks but, nothing. Having voltage at the ignition switch and the utility plug but none at the headlight switch has really got me stumped. Any thoughts are appreciated. Also tried other batteries that work with other ATVs and Tractors but nothing works with this thing.
