Kawasaki 220 starter problem

[johndeere2210]

I have two Kawasaki 220 four wheelers. Last night I went to start one of them and the solenoid just clicked. I checked the battery and it was charged up with clean connections. I took the solenoid off the other one and installed it on the one that would not start and it just clicked. I switched batteries and the solenoid still just clicked. Am I missing something? I really don't want to replace the starter unless it is absolutely neccessary. Any helpful hints will be appreciated.

 

[OKnewguy]

I have 2 bayoo 220's also and have had problems with both of them (starting that is), it has always turned out to be a problem with the ignition switch or the wires going to the switch. I would sugest trying to jumper between the 2 contacts on the solenoid for the switch. This should tell you if the problem is in the switch circuit or the actual solenoid, if the switch circuit is at fault, good luck!!! I tried to find the problem in one of mine and never could find the exact problem (it seemed like i was chasing ghost), i eventually put a push button switch on the plastic cover thing that has the neutral/reverse lights. The other bayou I was able to clean up the actual contact in the start switch which has taken care of it, but if this one acts up I will just put in a switch like the other one. If you bypass the original switch, get a decent switch for marine applications.
other then this goofy little querk these have been GREAT machines and have done a ton of work and insane amounts of play.
Good luck

 

[johndeere2210]

Thank you for your reply. I was able to diagnose and repair the problem this evening. It turned out to be the connection where the ground cable is bolted to the engine block just behind the rope starter. I cleaned the cable and block with some steel wool and the problem went away. (cheaper than a new starter). I also had one tail light that was not working and since I cleaned the ground connection, it is working also.
You are right, they are great little machines and we too have done mountains of work with them. We also love to go on evening rides across the country side. I haven't figured out why, but the wild life doesn't seem to be intimidated by the four wheelers. We have seen some great stuff down along the river. Thanks again for your reply. /forums/images/graemlins/cool.gif