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Issue: Machine has Power But starter will not Turn Over
- Make sure you are getting a brake light, most machines have a safety that will not allow the starter to turn without the brake being held.
- If you are getting a brake light, check and make sure that when you push the start button that the light does not go off or dim. This would indicate that you have low voltage on you battery and need to charge it.
- Check that the button is making contact to engage the starter relay. You should hear a clicking or see your light dim slightly if the button is working.
- If you don’t get a click from the relay test your starter relay. This is done by simply jumping across the two leads on the starter relay (bridging the connections with something conductive to complete the circuit). If the starter spins, your issue is in the relay.
- If your brake light is not lighting up when you hold either brake and you know the light is good. Replace the brake sensors and retry starting the machine.
- Weak voltage can be solved simply by charging the battery. If however the battery had a cracked or bad cell in it the battery would need to be replaced. Refer to the number on your battery to help identify a suitable replacement. (Most commonly used battery is 4/5Ah battery.)
- Replace Left multi function switch, and retry startup procedure.
- Replace the starter relay. Affix one wire to each side of the relay (it should be a wire from your starter to one side and a wire from you batter to the other side of the relay. Then plug it in to the harness). Repeat the starting procedure.
Not Starting (Machine turns over but will not start)
- Test for spark.(Remove the spark plug from the block, place it in the ignition coil and ground it to the engine. From here turn the machine over as if you were going to start the machine.) *Note: If you don’t have the spark plug grounded it might shock you slightly. Inspect the tip of the spark plug and if it is sparking your issue is elsewhere.
- Check fuel flow to carburetor. If you are getting fuel to the carburetor check and see if the plug is wet. Another way to check if its fuel related is to spray a little starting fluid on the air filter and see if it pops off from that. If it starts with the starting fluid, and runs for as long as the starting fluid is around then that would mean it is a fuel related issue. Also check to make sure there is no blockage on your air intake to keep the air/fuel mixture correct and keep the machine from flooding out.
- If you checked step #1 and step #2 and still having an issue starting your machine it could be a compression related issue. Check the compression of your machine with a compression tester. The compression should at the minimum 120psi. When doing the compression test, make sure you either have the carburetor disconnected from the manifold, or the throttle open.
- There are three components that contribute to spark. If you have no spark, the CDI, ignition coil, and stator are the three components that it could usually be. To test the CDI with an ohm meter. If you don’t have an ohm meter you can just use trial and error with this part. Order the CDI box and replace to see if your spark returns. If the CDI doesn’t seem to be the issue, the next easiest part to replace would be the ignition coil. This part can also be check with an ohm meter. Check the web or call a local service center for how to properly check this. The third component would be the stator. This is the hardest of the three to replace but again can be tested with an ohm meter. I would recommend checking with your local service center on how to complete this test. Lastly it could be a kill switch remaining open causing the machine to not spark. You can eliminate all of the kill switches by removing the black/white wire from the clip that plugs into the CDI box. If you get spark after this one of your kill switches is bad.
- Stock carburetors are not serviceable the only way to salvage them is to blow them out with compressed air. If this does not work your best bet is to just replace them.
- If your compression is slightly off check valve clearance. Adjust valves and re check compression. Inspect for bent valves, scored head, scored cylinder wall or seated piston rings. Replace defective part.