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Raptor relay buzzing & eating batteries, Update: Still does it

851 Views 64 Replies 7 Participants Last post by  QuadManiac
Most of us will know by now the sound they make with a weak battery. Click click click.

I was busy with my previous career so I couldn't put my mind to it. So I just started replacing parts. First I did the solenoid/relay under the seat. That's where it sounds like the noise is coming from. Nope. Then I just thought it had to be a worn starter that was drawing too much out of the battery. Its a 2001 with original starter so that must be it right? No.

Then I finally had some time to think about this. I bought a new battery again. I thought maybe the valves are way out of adjustment and making it start hard and run bad. And it should be done anyway. So i tore it apart and adjusted the valves. The exhausts were way too loose. I really thought it was part of the problem but no. Changed nothing.

The I watched some diagnostic videos. I figured out it probably isn't charging. I went out and bought a cheap analog multimeter. I discovered that the volts with the new battery disconnected were the same as when the battery was in the bike and running. So aha. It ain't charging.

I unplugged the stator and tested it with the multimeter with the bike running

Now this test showed that the stator was definitely working. But maybe a tad weak. But I am not used to this multimeter. So its probably fine. Then I tested the output coming out of the rectifier/regulator. And it read zero. Zilch. Nothing

So I thought I finally solved it. Ordered a new rectifier/regulator. Put it on. I go to start it. I noticed it click a couple times but then it fired up. I didn't think much of that because maybe the battery was a bit drained (even though I have been trickle charging it all night and day)

I put the multimeter back on the battery with the bike running and it is showing that its charging. Its hard to tell with the analog multimeter but the needle is showing 2 values higher when the bike is running. So say 12 volts when off and 13-14 volts with the bike running at idle. So... its charging right ?

Well it is still clicking before it starts. A couple clicks then the starter kicks in and then it starts. And it doesn't turn over very convincingly. So its doing the same thing still. I bet when the bike is hot, I wont be able to restart it at all. It will just click. That is what it always did. So it is not fixed.

Thoughts ?
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I’m not a stator expert. If I read your posts correctly the post showing the meter when the stator is plugged back in shows a higher voltage that the picture of when the stator was unplugged (which should have been battery voltage). That would make me think that the stator is producing voltage to charge the battery.
Analog meters their place in electronics diagnostics, I would have kept it as both analog and digital is nice to have.
You are reading it correctly. I came to the same conclusion.

And yeah. That is why I got the analog one. My new digital one is making even less sense. It is counting down to zero volts on my trucks perfectly good and charged battery. So now I am Youtubing how to do the most basic function on a digital multimeter.

I really have to call it a day. And stop beating my motherf**king head against a wall.
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You are reading it correctly. I came to the same conclusion.

And yeah. That is why I got the analog one. My new digital one is making even less sense. It is counting down to zero volts on my trucks perfectly good and charged battery. So now I am Youtubing how to do the most basic function on a digital multimeter.

I really have to call it a day. And stop beating my motherf**king head against a wall.
Among other readings my digital meter has separate settings for AC voltage, DC voltage, and ohms. If you don’t have it set to what you are trying to measure it will not give you accurate readings. If you want post a picture of the meter and what you are trying to measure someone will make sure your headed in the right direction.
Bonus. Search “motor age #73” on youtube. That guy has several good videos on how to measure and diagnose automotive electrical problems. Well worth the time to watch.
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My meter has a separate spot for automotive 12 volts it looks like. And the regular volts settings don't work the same way I guess.

Anyway I got the meter figured out.

The battery with the engine off reads 12.36 volts
Reading from the stator output bike idling : 3.39 volts
Reading from battery with bike running and everything plugged in : 14.75 volts

Is 3.39 volts low ? The Partzilla guy on Youtube says he should be 40 volts. Or is my settings just different?
That sounds about right as far as when it’s charging. A vehicle is the same way with around the same 14.** volts.
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And..... First good weather in forever and it still does it when hot. Click click buzzzz , listen here Streamable Video

Its funny how human psychology works. I wanted so bad to believe it was fixed. I just went up the mountain 60 kilometers in and back. I could have easily been stranded. But it was running soooo good I just thought it was fixed. All that extra tune up, valves adjusted, fresh oil, new oil and air filters, fresh premium gas. Its amazing. These things run well with proper maintenance

Anyway Im pretty sure its the ignition key. But I better go check the battery. See how much it has

edit: 12.61 volts

It better be the motherf**king ignition key. It was the ignition key for the other guy with his similar thread. Its only $20. Here i wait again.
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Damn frustrating, I feel for ya brother…
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When wires get hot, burn up, or smoke it is because too many amps (more amps than that gauge is rated for) went thru them. The cause could be the load demanded more than it should have, the wire connected to ground, or a loose connection up stream between that point and the battery. In the example of the latter the load still needs the same amount of amps so more amps has to pass thru the wire to account for the resistance or voltage drop of the loose connection.
Your going to have to figure out the cause of the excessive amps.
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Now it's really screwed. It used to cure itself after it cooled down. It's been cool for hours and now it is just buzzing and the positive and negative cables going to the battery are getting hot.

I guess this is better for diagnostics.

The volt meter reads 12.75 volts at the positive post of the solenoid all the time. When I hit the start button , only 5 volts is getting to the other side of the solenoid post.

I pulled the solenoid bolts and checked that they were clean. I wire brushed the ends.
There is some corrosion and oxidation on both cable ends going from the solenoid to the starter. But I've had this problem on this quad for 10 years. I am going to make a seperate cable and just replace it to see if thats it. But i really dont think it is. Is there any way to ohm out a cable from end to end to see if the corrosion is really a problem ?
I tried crimping it a bit so those marks are new.
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Yes, switch your multimeter to the ohms setting and see the resistance by probing through the both ends of the wire.
This sounds like a electric short somewhere. Either a break inside the wiring or bad connection. Crimping it down won't fix it. Try using a jumper wire from the starter to the battery when it's buzzing and see if it cranks over the engine. If it does then it's something in the wiring. If not then replace the starter. Also test the ohms of the ground locations to the battery negative post to see if you have resistance there. You need to basically just start testing each component when dealing with electrical issues. Start with the basics and keep going. It's stressful at first but once you get the hang of it it goes fairly quick.
I disconnected the black cable from the solenoid (the one in the picture) and then checked the voltage on that post when I pushed the start button. It still loudly clicks. But it does show 12 volts.

With that whole cable and starter eliminated , it seems to me it is something before the solenoid
This sounds like a electric short somewhere. Either a break inside the wiring or bad connection. Crimping it down won't fix it. Try using a jumper wire from the starter to the battery when it's buzzing and see if it cranks over the engine. If it does then it's something in the wiring. If not then replace the starter. Also test the ohms of the ground locations to the battery negative post to see if you have resistance there. You need to basically just start testing each component when dealing with electrical issues. Start with the basics and keep going. It's stressful at first but once you get the hang of it it goes fairly quick.
Will do thanks. FYI the starter is new. As is the solenoid. And it is charging good. Stator is good , reg/rectifire is new
The volt meter reads 12.75 volts at the positive post of the solenoid all the time. When I hit the start button , only 5 volts is getting to the other side of the solenoid post.
You are starting to isolate the problem. What changes in the circuit when the solenoid is activated?
In case this might be helpful , I used to jump start this quad with a car battery and jumper cables when it did the clicking. Because I assumed that I just killed another battery. And it would work. Not always , but jumping it with a car battery would work. And there would be no smoke or anything. I bet the battery was in better shape or fine when I was doing this though. Because it's doing the same with a brand new battery

And when it started , the quad ran fine. Until I shut it off again
Is the car battery in the car with it running when you try to jump start the quad? Be careful because car alternators are much more powerful and can fry your electrical on the quad.

Car batteries have a lot more amps than ATV batteries. The car battery is able to shove more amps through wires that have resistance. Had a old Chevy pickup that had weird electrical gremlins that were similar. The grounds were junk because of the guy that "restored" it didn't understand electrical or mechanical and there was corrosion through a lot of the wires. I replaced everything and now it runs better than any new vehicle even in extreme cold. Sometimes you'll have a wire with corrosion or break inside that you don't see and it'll cause a lot of issues. Have you replaced both your battery cables yet?
Is the car battery in the car with it running when you try to jump start the quad? Be careful because car alternators are much more powerful and can fry your electrical on the quad.

Car batteries have a lot more amps than ATV batteries. The car battery is able to shove more amps through wires that have resistance. Had a old Chevy pickup that had weird electrical gremlins that were similar. The grounds were junk because of the guy that "restored" it didn't understand electrical or mechanical and there was corrosion through a lot of the wires. I replaced everything and now it runs better than any new vehicle even in extreme cold. Sometimes you'll have a wire with corrosion or break inside that you don't see and it'll cause a lot of issues. Have you replaced both your battery cables yet?
Yeah. it wasn't a good idea at the time but I was desperate. I am not doing that anymore and haven't subjected any of the new parts to it.
I think I'm just going to take both leads off the solenoid and cross them. The current should just connect and wind over the starter
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