Honda Quad - Siezed Starter Motor

[muddy42]

Darn, I went and jinked it by saying my quad was running well yesterday. Today the starter motor went on my 2009 Honda TRX420 manual. I know a lot of you have Honda quads so hopefully someone has relevant experience.

So when I try to start the quad there is only a single click coming from the solenoid. The battery is relatively new and fully charged, I even tried adding a larger car battery in parallel, nothing. Im pretty sure the solanoid is OK, it shows continuity across the poles when I depress the start button also I get 12v to the starter motor in the same situation. I have tried banging the starter motor whilst cracking to no avail. The pull start works fine and the quad is useable that way. So Im pretty sure the issue is with the starter motor, it had been sounding a bit weird and 'wizzy' for a while. I think either the external cog or internal bits have seized.

I think I could do the replacement work myself, the issue will be sourcing the part. Tentative googling reveals the following options:
- New OEM Honda starter motor (£550 so Im not that keen, given the age of the quad)
- aftermarket starter motor (£30 definitely Chinese - £100 maybe Chinese sold by UK company ) does anyone have any recommendations or experience with any of these?
- remove and rebuild starter motor (brushes etc. £30) Ive never done this, but willing to try).

Any advice or experience appreciated! Thanks,

 

[Rake Aboot]

Rebuild isn’t that hard and plenty videos on YouTube to show you how

Can you access the motor with the end of a screwdriver to see if the rotor is actually free ?

Clicking solenoid is usually a flat battery so well worth triple checking or using a booster pack.
Disconnect the battery and measure the voltage

 

[muddy42]

Rebuild isn’t that hard and plenty videos on YouTube to show you how

Can you access the motor with the end of a screwdriver to see if the rotor is actually free ?

Clicking solenoid is usually a flat battery so well worth triple checking or using a booster pack.
Disconnect the battery and measure the voltage

Thanks. Ive havnt got access yet - i need to get the air box off. I think tomorrow I’ll get in there and get the starter out and put everything back together. I might as well because I cant get it working

Im pretty sure its not battery related. The battery is only a few months old, sits around 12.8v and was plugged into a trickle charger. Plus ive tried a bigger CCA battery.

 

[Greenmist]

I've swapped a few, not a big job, before you do anything, have you checked all the connections to make sure they're tight

 

[Rake Aboot]

Tight and clean ! Corrosion on the connectors can cause issues like this as well

 

[eldon]

You can use a jump lead to confirm a good earth connection direct from the battery.

 

[muddy42]

Tight and clean ! Corrosion on the connectors can cause issues like this as well

Thanks. Ive done a bit of this - battery and solanoid connections but I will check the starter motor connections when I get in there properly

You can use a jump lead to confirm a good earth connection direct from the battery.

Thanks. I think I follow you. Ive checked the main earth / negative to chassis near the battery and that this has multimeter continuity to the starter motor housing.

I've swapped a few, not a big job, before you do anything, have you checked all the connections to make sure they're tight

thanks. Where did you source the replacement starter motors from - OEM or China?

 

[eldon]

I'd just buy aftermarket for around £60 as you'll get a lot of those before you get to a Honda price.
Usually it will be worn down brushes, or the internal magnets glue has let go.

 

[Greenmist]

Thanks. Ive done a bit of this - battery and solanoid connections but I will check the starter motor connections when I get in there properly

Thanks. I think I follow you. Ive checked the main earth / negative to chassis near the battery and that this has multimeter continuity to the starter motor housing.

thanks. Where did you source the replacement starter motors from - OEM or China?

In all honesty I don't know, it was a fair few years ago on a different estate, they would have come from the local garage, but where he sourced the parts is anyones guess, I don't think they were the price you quotes as the boss at the time was tighter than clenching duck and would have refused to pay that amount

 

[nic531]

Darn, I went and jinked it by saying my quad was running well yesterday. Today the starter motor went on my 2009 Honda TRX420 manual. I know a lot of you have Honda quads so hopefully someone has relevant experience.

So when I try to start the quad there is only a single click coming from the solenoid. The battery is relatively new and fully charged, I even tried adding a larger car battery in parallel, nothing. Im pretty sure the solanoid is OK, it shows continuity across the poles when I depress the start button also I get 12v to the starter motor in the same situation. I have tried banging the starter motor whilst cracking to no avail. The pull start works fine and the quad is useable that way. So Im pretty sure the issue is with the starter motor, it had been sounding a bit weird and 'wizzy' for a while. I think either the external cog or internal bits have seized.

I think I could do the replacement work myself, the issue will be sourcing the part. Tentative googling reveals the following options:
- New OEM Honda starter motor (£550 so Im not that keen, given the age of the quad)
- aftermarket starter motor (£30 definitely Chinese - £100 maybe Chinese sold by UK company ) does anyone have any recommendations or experience with any of these?
- remove and rebuild starter motor (brushes etc. £30) Ive never done this, but willing to try).

Any advice or experience appreciated! Thanks,

done starter motor brushes on motorbike engines and they were a simple enough job. cannot imagine any harder, just a little bigger

 

[disco_ike]

There is a known issue and repair for a similar thing on Land Rover starter motors. The internal contact wears so the plunger doesn’t connect both terminals and start it.
I would get the starter off and identify where these contacts are and get them out. On a disco 2 you can do it without removing the starter motor not sure on a quad but probably the same thing.

 

[Smellydog]

I've not read all the comments but can you bypass the solenoid and jump directly from a battery.
Connect on the live + cable into the starter. Obviously the - side or earth and you on the battery acting as a solenoid.

That should or could eliminate the starter if it cranks etc.

 

[eldon]

I've not read all the comments but can you bypass the solenoid and jump directly from a battery.
Connect on the live + cable into the starter. Obviously the - side or earth and you on the battery acting as a solenoid.

That should or could eliminate the starter if it cranks etc.

Just be mindful of sparks and hydrogen interacting
Best to connect live last at the starter motor end, than the battery.

Beware!

 

[sikastag270]

had same happen, new starter easy to fit and quite cheap

 

[muddy42]

There is a known issue and repair for a similar thing on Land Rover starter motors. The internal contact wears so the plunger doesn’t connect both terminals and start it.
I would get the starter off and identify where these contacts are and get them out. On a disco 2 you can do it without removing the starter motor not sure on a quad but probably the same thing.

Thanks, the starter on this variety of quad is buried right in the centre of the quad under the airbox. Really awkward but I've got there.

I've not read all the comments but can you bypass the solenoid and jump directly from a battery.
Connect on the live + cable into the starter. Obviously the - side or earth and you on the battery acting as a solenoid.

That should or could eliminate the starter if it cranks etc.

I've done that and created sparks! but more that that I can tell that the solanoid is working because it has continuity and I get >12v to the starter when I push start. I've cleaned all the electrical connections and they seem fine.

I hate having machines in bits for things to get lost or myself to forget how its reassembled. I'm going to order a new starter from Quad bike Wales or ATV city and tackle the job in a few days. Then I can guarantee reassembly and that the quad will only be out of action for a few hours.

 

[Smellydog]

I've done that and created sparks! but more that that I can tell that the solanoid is working because it has continuity and I get >12v to the starter when I push start. I've cleaned all the electrical connections and they seem fine.

You might get 12v but not the amps. The test determines if the solenoid or starter is the issue.

If you got sparks only when connected to the starter directly then it's the fault. An initial spark and then starter operating it's the solenoid.

 

[muddy42]

You might get 12v but not the amps. The test determines if the solenoid or starter is the issue.

If you got sparks only when connected to the starter directly then it's the fault. An initial spark and then starter operating it's the solenoid.

Yes I've also tried that. Plus Ive taken the quads battery and wiring out of the equation - disconnected the quad's battery and rigged up a car battery directly to the starter motor - sparks but no action. I think something is seized inside the starter motor?

 

[.270s202]

Just done same to mine, albeit a 2017 foreman but starter is in same location I believe, they are super common for seizing solid, I put a genuine one on only due to original lasting 9 years of abuse, although im sure some of the aftermarket ones are just as good if not identical,

 

[muddy42]

Just done same to mine, albeit a 2017 foreman but starter is in same location I believe, they are super common for seizing solid, I put a genuine one on only due to original lasting 9 years of abuse, although im sure some of the aftermarket ones are just as good if not identical,

Good to know. This is the original starter motor, owned since new in 2008, so its done well. I've just ordered an aftermarket one from Quad bike Wales £100 inc VAT and postage.

I will keep the old starter motor so I can examine it, test it and potentially rebuild it incase of issues.

 

[bullet chucker]

Good to know. This is the original starter motor, owned since new in 2008, so its done well. I've just ordered an aftermarket one from Quad bike Wales £100 inc VAT and postage.

I will keep the old starter motor so I can examine it, test it and potentially rebuild it incase of issues.

You say that? Truth be known, changed that working now. Round ones to the old one, lets move on!

BC.