Welcome to the forum

 

Did you reconnect the ground link at the top motor mount?

 

No I did not, Which ground wire connects to the motor mount? The one directly off the starter motor housing?

 

Actually on the 05 it is from the frame to the starter motor mounting bolt

#13 in the 05 parts breakdown

#20 in the 04 parts depiction

#47 on the 2000 depiction

 

Actually on the 05 it is from the frame to the starter motor mounting bolt

#13 in the 05 parts breakdown


















#20 in the 04 parts depiction

















#47 on the 2000 depiction

Oh then yes the ground is connected to the frame and the motor housing. I can hear the click when I turn the key and but then nothing happens

 

Put one end of jumper cable on the neg side of the battery and connect the other end to an engine part and try starting - if that works then the ground is faulty - if not, the solenoid may be making good enough contact to measure voltage, but may not be supplying current - may just be a bad solenoid.

 

The hot wire on the starter motor wasn’t making a good connection so I tightened up that nut, got a good crank out of it and it started(Off spray) and now won’t crank again, now the voltage drops to about 4v when I crank and i’m getting continuity between hot on motor and ground but they aren’t touching anywhere. Could they be touching inside the starter motor?

 

When you tighten the cable on the stud of the starter motor, you have to hold the installation nut to prevent the stud from turning and breaking the insulators outside and inside the starter motor housing.

I have a 10mm wrench that I ground down to be thin enough to hold the nut below the cable as the top nut is tightened.

 

So the cable would go between the two nuts, And if i’m reading continuity did I already break my insulation?

 

There has to be continuity to ground through the motor or it would not run - the only way to tell if the motor is bad is to take it apart and check that the individual windings on the armature have continuity to their respective commutator and that the windings are not shorted to each other or to the armature core.

 

Do you have any ideas as to why the voltage is dropping to 4v when I try to start it, it spun fine the other day once but then stopped. I have it hooked up to a jumper so I know it’s not a bad battery.

 

If there is 12+ volts on the battery side of the solenoid and 4 volts on the starter motor side of the solenoid when trying to start, it's a bad solenoid.

 

The voltage on the battery side drops to 4v, the solenoid clicks rapidly because it keeps making contact then breaking when the voltage drops then making again when voltage goes back up

 

That is an indication of a weak battery or a poor connection

 

I pulled apart the starter after determining that was the issue, found the magnets on the walls broken and the resin stuff covering the copper was all dried and breaking off

 

That's usually an indication of someone whacking the starter with a hammer to get to crank one last time.

 

That makes sense there are small gouges on the outside of the motor assembly, I got the atv used not too long ago so it was probably beat on before