payne

16 minutes ago, Frank Angerano said:

Go and  buy an easy out kit and drill it out with the approximate size bit and back it out.  
Heat will be key here so tread lightly.  Drill out the center of the stud carefully and go in with the easy out.   

I posted a pic of the extractors I have. Aren't those easy outs?

I have these 

Bottom one came out fine. Top one broke.  I may have rushed that one or not hot enough. What should I do next?

On 3/9/2020 at 9:32 PM, Frank Angerano said:

I do recommend a way to clean them up. 
Take a look at this last project i did. 
 

 

Water sand and apply a clear coat thats flexible and durable to chemicals.  

Let me know what you think. 
 

What clear coat did you use?

I'll give it a try. I wish they were bolt head, not allen.

Them breaking off is what I'm worried about. Is there any sort of repair wrap that I could use rather than removing it?

Think propane torch would heat them up enough to loosen? I dont have cutting torches. 

15 minutes ago, Frank Angerano said:

Fresh spark plug as well. 

Already got a new one in it. Next problem.....how to remove the bolts for the header. Very rusty!

4 hours ago, MarkinAR said:

Sorry to jump in about a dozen conversations behind but if the relay is clicking and it's not reliably starting it's most likely the solenoid.  The relay clicks closed and throws electricity to the solenoid to close it.  If it's not closing reliably then voltage doesn't get to the starter.  My oldest runs through solenoids constantly because of mud and water.  They get wet inside and corrode in days and then they're trashed.

Seeing as the parts are so cheap, I'll probably get a new relay and solenoid 

The exhaust is swiss cheese, so it needs removed.

3 hours ago, MarkinAR said:

Sorry to jump in about a dozen conversations behind but if the relay is clicking and it's not reliably starting it's most likely the solenoid.  The relay clicks closed and throws electricity to the solenoid to close it.  If it's not closing reliably then voltage doesn't get to the starter.  My oldest runs through solenoids constantly because of mud and water.  They get wet inside and corrode in days and then they're trashed.

Seeing as the parts are so cheap, I'll probably get a new relay and solenoid 

That thing is tiny, lol. Does it last long enough to crank on it for awhile?

That looks great! It may be a lil more work than I'm willing to do. Not sure. What grit sandpaper do you use?

What mini battery jumper do you use?

Thanks again. Think it was a combination of partially broken wire coming from ignition, bad/corroded connections things like that. I was actually fixing it for my brother in law. He's wanted a quad for few years now and he found this cheap,  not running. I'll post some pics when I'm done. Plastics are faded real bad. Was gonna try a heat gun on them or do you suggest something else?

I have a CFMOTO now, but had a 08 Rancher 420 and 87ish Bayou before.

Think I got it Frank! Used my lawnmower battery and it started right up. I think I'm gonna get a new relay because its hit or miss with it it seems. Thanks for all your help, I greatly appreciate it!

I take that back. Removed hot wire to starter. Connected test light to it at it lit up when I jumped the starter button wires. Light looked kind dim. Thinking maybe my battery is bad. It has 11.2v when no load is on it, but I have a trickle charger on it.

I'm gonna try and see if my lawn mower battery does any different tomorrow.

8 minutes ago, Frank Angerano said:

Ok so relay clicks is a great thing.  I would remove, clean and reconnect all wires going to the starter and try that again.  

Ok, I do believe that I'm not getting power to the starter still though. I put I test light on the 12v wire coming into starter and jumped started button and the light didnt light up.

Now when I jump the 2 wires at the starter switch, the relay clicks but starter isnt cranking

Orange wire has power now, I found a broken wire.

Red wire going to key was nearly broke

No

Should the orange wire have 12v when the key is on?

Red/white and looks to be orange

Also, took apart starter switch assembly and verified no power going to it. 

Jumped out both wires at the switch and nothing

Removed and cleaned terminals on really, reconnected and jumped them out. Still no crank. Also none of the wires on the other realy are getting power when the button is depressed.

Thinking maybe the starter switch is bad?

Will do.

7 minutes ago, Frank Angerano said:

The kill switch is a common suspect with atvs that are left outside. Water gets inside and eventually fills and corrodes the inside. 
But if its in the on position and the engine starts like you said i think its ok for now. 

Try to use a bigger philips head  screwdriver on that screw for the kill switch.  If it still does not come out then drill out the head only and when you get the control off you can grab the rest of the stud with a pair of vice grips and spin it out.   
 

Take the ground wire off and clean it good and put it back on.  You may want to go get a can of dielectric grease clean and add it to all the electrical connections.  
 

So back to that red wire, it has voltage when you press the start button? If so thats good. 
Now do the same thing on the starter relay. Test all wires like we said in the last post and see if any get voltage when start button is pressed. This will tell you that the start button is working should you get power upon pressing the start button to any of those wires and thats a good thing if you do. 
  
Keep in mind a new relay may be needed and its cheap enough to get and easy to find.  I say this because if you get power to any of the wires on that relay when you press the start button means the relay is getting power and it should click. UNLESS there is a ground issue and that will be the next step.   
 

Back to the starter, i feel like you should disconnect the starter if its bad. Once you get that relay to click its going to send power to the starter and if you jumped the wires like you said and that starter is not  moving you could burn wires up so be careful.
 

I believe the state is fine. I have  connected the starter directly to a battery and it turns and starts the quad no problem. Just not with the start button.

I checked those wires earlier, but not with the button pushed in though. I will do that and let you know what I get.

Thanks for all your help. Are we able to message directly to one another on this forum?

I will check for power to those wires when I get home.

The bike must have been left out in the weather because every screw, bolt and nut are corroded when trying to remove them.

Wanted to look inside of the kill/starter/headlight switch, but cant get the 2nd screw out to look at it.

Kill switch doesnt move, but its stuck in the on position.

Oh, ok. So that red wire is only gonna be hot once the starter button is pushed?

Yes, brake handle is pulled, I'm confident the switch is in there, because the wires are still running out of it. 

Do these bikes only have 1 ground? I found the one under the battery tray a d is very corroded.

I will check for power to those wires when I get home.

The bike must have been left out in the weather because every screw, bolt and nut are corroded when trying to remove them.

Wanted to look inside of the kill/starter/headlight switch, but cant get the 2nd screw out to look at it.

Kill switch doesnt move, but its stuck in the on position.