Leaderboard

i did think about putting it on the plastic shroud that goes over the gear shift and diff lever and choke cable just left and below the seat but it's kind of prone to weeds and briars grabbing it and weather, of course a waterproof switch will be used.

Depending on the location of the solenoid, there's no real need to mount the button on the dash. You could easily mount it somewhere around the seat, within easy reach, with shorter wires. Momentarily handling that modest amount of amps shouldn't be any reason to up the guage significantly. I would think that 18g. would work fine.

Sounds like a good, solid plan. My guess is that if this solves the no start condition, there's no real need for a new harness. So I'd stay mindful of creating something that'll stand up over time.

I'm done with this thing..... i thought it wasn't going to start today, turn the key, click. turn the key, click, turn the key click, about 30 times... the battery voltage would drop about 1/2 a volt when i turned the key to start and it would hit... then it started about 3 or 4 times with no problem.... I'm confident it is not a physical Flywheel ring gear /starter gear issue as i did an experiment where i marked on the flywheel with a sharpie what position it would be in when the starter would not turn over, and it never was in the same spot. I'm confident it's not the starter or solenoid as i've bench tested them according to the manual and the good folks at O'reilly's have tested my starter and load tested the battery. I think the wiring is just not quite able to carry the load to mesh the flywheel and starter gear since it's the solenoids job to pull it in and mesh it. and of course when i short from the + lug on the starter to the trigger tab, it will spin every time, all day long with no issue. I'm trying to think of a way i can bypass the entire starting system/circuit..... what i'm thinking of doing is run a hot wire from the battery, to a momentary push button switch on the dash. and run a wire from the switch to the starter solenoid trigger tab. so when you want to start it, turn the key to on so you can have power to accessories and so the ignition will work, then to start it, press that button. and maybe one day when i get time, i'll buy a new wiring harness for the old gal... RM atv has them for $150.. so that's not too bad of a dent in the pocketbook. Plus after 20 years of being outdoors in this southeast Texas humidity... i'm sure thats an issue.