Hello hoping someone can help me out. I picked up this atv for my son a 110cc 2008 Gio atv 4 stroke. Thats all i know about it.
Tried to get it to run but when I push the start button it barely turns over, like once maybe every 20 seconds. The battery is at 12.85 volts standing. 11.97 when cranking but only 3-8 volts at the starter. Changed ground Wire, starter wire, coil, starter works fine on bench test. Also i noticed when I put the magneto cover on tight it wont crank at all like something is bent. Any ideas?

 

Sorry 3-8 volts on starter side of solenoid. Also there is a lever bracket on the right side of the bars. Their is no lever but there is a pin connected to two wires running into the harness. Could it be a safety switch? Lol also the tail lights come on as soon as you turn the key on possibly a short? or are they on all the time? Two wires, no switch. Headlights and H/L/off switch work.

 

I double checked my volts at the battery when cranking it and it dropped to as low as 4 volts. Think the starter is drawing to much?

 

let me get this straight, the starter is testing fine on the bench, you got dang near 13v standing, and less than that on the backside of the solenoid. and your starter sounds like whomp..........whomp.............whomp........whom p instead of nuhnuhnuhnuhvroooom.
sounds like your safety interlocks are satisfied if it is trying to crank. so, have you jumped the battery from your car or pickup truck? or use a jumper box and see what happens then(the extra juice from a jump can rule on behalf of a bad battery/dying cell). what does the voltage readings do if you jump the solenoid posts with a screwdriver?

 

I tried hooking up directly to the positive side of starter and grounded right to the starter housing from vehicle and same thing. I barely turns. Took out plug turns over continuously and great with no plug from the start switch. Dont think the starter is working under a load

 

Okay so I pulled the magneto cover off at their is a wear mark on the cover. The flywheel is making contact with the cover. Why would this be happening? Obviously something is bent, would it be possible to shave the cover a bit with a dremel? it does run i had it started last weekend for about 30 seconds three times. But i fried the starter.

 

so you don't see any other physical damage or misalignment issues while you're in there looking? hmmm....i reckon there ain't no way to turn/crank the engine and watch it spin, huh? dang, you got me on this one. something is out of alignment or the cover is slightly bent inwards in order for that thing to hit. hmmm......

 

Yes I was able to turn it over with the cover off and with the switch. But didnt get enough cranks battery died and had to go to work. It looked like the flywheel was fine from the few cranks I got. Its hitting between 11 and 4 looking at it from the inside.