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Posted by: CED
I had the same problem with the relay just clicking turns out my battery was no good.It would read 12 volts ,but when you would hit the button it would fall to about 2 volts.I replaced the battery and had no problems since.Take the battery out and connect some jumper cables directly to the leads and see what it does.
Posted by: CED
My starter was bad also,i found out about the battery after the fact.They have em on ebay,brand new for around $100.I payed $170,i found the ones on ebay after i had already installed the new one.It's not that bad just loosen the front engine bolt and the foot peg bolts and then pry the engine up with a crowbar.
Posted by: confusedbuyer
so when you put power straight to the starter it works? i'd say it's your relay (solenoid). mine would make the clicking noises too, but it didn't work. you can jump those 2 red wires (soleniod removed) to confirm it's your relay (use same gauge jumper). also, you are engaging the emerg brake before trying elec start aren't you?? i'd recommend getting the pull start for back-up.
to remove, first slam your nuts in a vice because it's just as much fun. seriously, you need to remove carb, and remove motor mounts on front. remove metal pegs and bolts holding them in place. then i used a pry bar to move motor to get access to wiggle the starter out at a goofy angle. i stood mine on end (shut off fuel petcock), and it was easier to see what was going on. you can replace brush plate on starter, or armature, rather than steep $$ it costs for a new starter. the starter is only held in by 2 long screws on the belt cover case side.
Posted by: confusedbuyer
don't forget you can replace starter parts, like brushes (which is usually what's worn out, costs about $35.)
Posted by: confusedbuyer
they ride against the armature with little tension springs behind them. they have a little copper wire on them (it's probably black by now from carbon wearing off the brushes). If you need, PM me with a fax # and i'll fax you a diagram and some relevant instructions.OR, you can take it to an electric motor repair shop (there should be lots of places that do that type of work) and they'll usually repair it for a nominal amount ($20 + parts). you can get the brush plate from Suzuki. you can check on-line to see a Suzuki microfiche diagram of the starter. in your search engine, type in suzuki atv parts, and it should give you a direct link.
if you do it yourself, make sure you clean the lines out on the armature (between each copper plate). the lines run at right angles to the brushes.
you can buy brushes only, as this is a Matsush!ta starter. that's why a starter repair shop might be able to help ya out there. In my case, my brushes were worn, and a tension spring was broken. let me know how it works out.
Posted by: confusedbuyer
what you'll find is the handle is a rubber boot that seals the hole it pulls out of. i don't think you should change that. ours has never leaked. as i recall, there are little rubber gaskets for each of the 4 screws that hold the pull start in place, plus a big gasket that seals the whole pull start unit. these are important to keep water and dust and crud out of your belt cover area. you may want to order new ones, or be careful not to loose the old ones, especially the little ones that go around the bolts.
Posted by: nedflanders
whoa, whoa, whoa! you can also replace the armature thru Suzuki for less than a starter. AND, if you decide you want to go with pull-start only, you still need to plug your old starter back into the hole where it was, or you're asking for problems with water and crud getting into the engine/belt case, thru the opening.
I don't trust starter shops as far as I can punt them. unless there are broken windings on the armature, i'd be a little suspicious. try for a second opinion?!
ALso, on Ebay, there is a guy selling totally rebuilt starters for $105. There are others selling them for more. the pull start from Suzuki is about $100, so for same $$ (and you still have it apart), you can get back to electric. While you'll have no problem pulling the pull-start, your kids will.it's a black rubber knob type handle which you hold between your split fingers when pulling (like Spock's Vulcan greeting of 'Live long and prosper'), and it has lots of tension. they'll have a tough time pulling and gripping at the same time. there is no "T" to the handle.
just some food for thought before you give up.
Posted by: ddtia
I asked the same ? in another post.
I tried to remove it with out disconecting the front eng bolt and could not do it. I also considered di assembleing the starter but decided not to.
LT80 responded saying it could not be done with out the front motor mount being disconected.
your post was kind of fuzzy but it sounds like the battery may be low that usually makes the relay chatter or the starter bedix is stuck that is if you say the starter spins but does not turn the motor.
Posted by: chris6
what does it take to remove the starter? do I need to disconnect the motor?
Posted by: chris6
turns slow, now relay clicks starter does nothing when you put power to the starter it turns
Posted by: chris6
I did a load test on the batt it was good (I wish that was the problem ). There is no easy way to remove the starter I found out. Guess i'll buy the pull start kit, the electric starter is expensive$$. When I jump the relay the starter turns slow, sounds bad, and the starter wire is heats up.
Posted by: chris6
I removed the starter and took it apart what do the brushes look like?
Posted by: chris6
Brought it to a starter shop they said the armiture is fried in the trash it goes. this is where the pull start comes in (buying one). thanks for the help offer.
Posted by: chris6
Sorry I didnt mean I was really gonna throw it in the trash. the guy at the shop showed me the winding they were burnt and shorted out. I will still use it as a plug. for the pull start I always ride with my daughter so I can start it for her.I ordered the pullstart on monday and it should be in friday. About the handle could you use a lawnmower T handle sounds like a good idea.
Posted by: freightrain
It depends on if you can reach the bolts. It may help to remove the bolts holding the footpegs on so that you can move them out of the way. I'm having a problem with mine at the moment. The relay clicks, but the starter doesn't bugde. Is it cooked?
Thanks,
Mike
