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  Topic Review (Newest First)
08-29-2019 11:07 AM
rrbrew Thanks to everyone for the help. I did get the quad started. I'm pretty sure it was a result of really bad/dirty relay contacts.
08-27-2019 07:55 PM
tom bauer To eliminate the starter safety circuit, ground the yellow/black from the CDI. This will close the starter cutoff relay (you should hear it click) so that the start switch will directly control the starter relay (solenoid)
08-20-2019 07:33 PM
cory52000 if i remember the manual on here is year specific and may not match. i remember the baby blue wire is is from the neutral switch but beyond that i am not sure. i am not positive with out doing some research but i think one is for the start circuit and the other is a rev limiter for reverse and possibly a parking brake. i am pretty sure they used the same relays up to 2004 so the testing procedure for the relay should be the same as the manual and them you can rule them in or out. also pretty sure they are the exact same so you might try swapping them. as to the wiring diagram if you are going to keep the machine at the point the best 30 bucks you will ever spend is the clymer paper manual for the warrior. it has all of the wiring diagrams for every year and really easy step by step instructions for testing every electrical component.
08-20-2019 06:25 PM
rrbrew Troubleshooting some more right now. I have the master on/off switch turned on right now and whatever these two hookups are, are quite warm to the touch.

I checked the wiring diagram found on this website and I thought that these were the starting circuit cut off, and the neutral relay, but they have different color wires going into them than the service manual says they should. Image below.

The Green connector has six wires total going into four connectors, The order is: connector one has light blue, white/black. Connector two has brown. Connector 3 has green/white, green/white. Connector for has light blue.

The white connector has four wires: brown, Brown, blue/white, yellow/black.

Not to sure where to go from here, could use some next steps. As always, I appreciate it.
08-19-2019 09:58 PM
rrbrew Ignore my above post. Looks like a bunch of others are having this problem. @cory - I'll try your test tomorrow, looks like you posted it in a prior thread.

08-19-2019 09:47 PM
rrbrew So I got the service manual out tonight and followed through their troubleshooting the start procedure. The 2nd step had me check continuity for the start button itself (page 7-13) in the manual. I just want to confirm that I can run the continuity test with the master on/off switch in the "off" position.

I did note there was a lot of dirt inside the connectors. I blew it out with compressed air and gently took a small file to the connections. That didn't work either.

One thing that I tried but couldn't get to work was the kill switch. I tried a continuity test on that because I know it works but couldn't find the right place to test the wires. Is the Black, Red/White, Black/White wires all in the same connectors, or is it spread across multiple connections? If I could get this continuity test to work, then I'd feel real good about the start switch being broken.
08-19-2019 03:59 PM
rrbrew I did try to start the bike with the clutch pulled in while the bike was in neutral. Nothing. Dead silence.

I have not tried to bypass a clutch safety switch because I didn't know there was one....
I will test the two relays tonight.
08-19-2019 03:18 PM
cory52000 https://www.ebay.com/itm/Neutral-Rel...8AAOSwh5Zcdlaf
there should be 2 of these if i remember correctly. one of them will be from the neutral switch and i think the other might be the reverse cut off.

will it spin with the clutch pulled. have you bypassed the clutch safety switch?
08-19-2019 03:14 PM
cory52000 test the 2 small wires that plug into that. put the red lead of your meter in one side and black in the other. should show no voltage and should show voltage when you hit the button
08-19-2019 03:12 PM
cory52000 that is the solenoid i suspect it is the relays should be 2 small black boxes near the solenoid they receive the signal from the safety switches and tell the cdi it is ok to go
08-19-2019 01:11 PM
rrbrew www . amazon . com/gp/product/B07T58P6B2/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

Sorry - one more try...having trouble posting a link to Amazon. I put spaces in to this link. You'll have to add them back.
08-19-2019 01:10 PM
rrbrew Alright - here is what I bought:

It says "Starter Solenoid Relay".
@cory52000 - could you post a link to the type of relay you are referring to so I can troubleshoot that?
08-19-2019 01:09 PM
rrbrew Ignore - upping post count.
08-19-2019 01:08 PM
rrbrew Ignore - upping post count so I can post a link to what I bought..
08-19-2019 11:16 AM
cory52000 it could be the switch or wiring but most likely its is one of the relays either not connected or is bad. not the starter solenoid
08-17-2019 11:14 PM
indybama Id say u either have a short in the wiring from the start button to the selonoid, the wires may be broke off the switch in the housing, or it could be its just wore out.

Ill look tomorrow, i may have one layin around

Sent from my SM-J327VPP using Tapatalk
08-17-2019 09:06 PM
Electric Start not working - can jump start

New here! I've used this forum for several days to get where I'm at through searching but I'm finally a bit stuck or couldn't find what I'm looking for.

Working with a '97 Warrior that hasn't been run in 12 years and I was able to get it running today by the screw driver trick between the solenoid relay posts. I'm still not able to get it to start with the button on the handle bar.

Here's what I've done so far:
- Brand new battery (confirmed 12 volts with multimeter)
- Brand new starter solenoid relay but that didn't seem to matter
- Cleaned ground wire on battery connection and engine ground
- Checked the fuse itself, it has continuity.

Here's what's working when I turn the ignition switch on:
- Headlights work
- Neutral light works
- Reverse light works

When I hit the start button I get nothing...NOTHING. No clicking, just silence. Like I said above, I learned the screw driver trick on this forum today and it started it up. The kill switch on the handle bar worked shutting it off.

Not sure where to go next. I'd appreciate the what to test next and how. Definitely a beginner when it comes to working on these things. Thanks!

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