I have a 2021 CForce 400 with approximately 700 miles on it.  When I turn the key on, I always hear the fuel pump energize, and when I hit the green start button it will usually start, but sometimes I get nothing and other times I can hear a "click".  If I turn the key off and then turn it back on again, most of the time I can then start it up.  This issue happens year round, not just during the cold weather months (I have a battery tender that I use during the winter).  It has never been submerged in water and it is always kept in a garage and out of the elements.  I live in Minnesota.

I replaced the starter relay under the front panel/hood.  I purchased a new solenoid that I am going to install as well.  Wondering if I have a bad contact in the switch housing (green start button).  I am at a loss as to what the issue is.  I have one of those ordered too.

Any thoughts or ideas  . .

Thank You in advance for any information you have for me!

David

[2015 Z Force 800 53/Trail EPS]

There were some bad key...and kill switches out there. Might test them

That would make sense if when I turn the key off and then back on again that everything works.  The kill switch is part of the starter button housing, which I am going to replace as well.  I know chasing parts is not the best way to go, but it's cheaper than bringing it into the dealership.  I will have under $100 invested in new parts.

With our Minnesota snow, I need to have my ATV available and ready to plow snow.

Thank You for your reply and advice/suggestions!!!

Maybe related, I got rust on the ignition key housing.  Had to take it apart to clean it up, lube it back up and everything works now like a charm.  Every now and then I spay son WD40 in there just for good measure and I have not had the problem reappeared.

Hi DRVMN,
As bizarre as it might sound a battery conditioner can ruin your battery, despite the voltmeter giving you a reading of 12V.

A true test of any 12V battery is to test it under cranking load i.e. are you getting 12V or above when cranking or are the volts dropping significantly during cranking. If the Volts are dropping significantly under cranking your battery is on the way out. Conduct a dry discharge test, observe all the battery cells during this test, if any one cell is bubbling its shot. But, be very careful whilst conducting the dry discharge test, disconnect the battery from the ATV, in fact safer if you remove the battery from the ATV. Make sure you are utilising as safe and good quality dry discharge tester, not the cheap dangerous versions from Amazon or Ebay.  Probably safer/cheaper/easier to get a dry discharge test at your local battery shop/supplier.

Never ever keep your battery permanently connected to a battery conditioner, it will overheat, sulphurise, and cause battery cell plate material to short out the plates in a battery cell as it collects in the base of the cell. This will significantly reduce the performance of your battery and give you the kind of start problems you are getting i.e. one minute its OK then another it's not OK.

Sulphurisation i.e. sell plate material dropping to the base of the cell and shorting out the cell is compounded in the majority of batteries fitted to all ATV's. This is because the battery dimensions are 75% less than say a 12V battery on the average car. If ATV batteries are kept permanently on charge the whole process of sulphurisation is exacerbated and battery performance reduced to all time low.

Yes of course, keep your battery charged, do not permit it to drop below 12.5volts, but do this once a month. When the volts drop bellow 11V on a regular basis this too can cause sulphurisation and eventually destruction of your battery with the exact symptoms you are getting.

Try to stop diagnosing by substitution of parts in the start circuit that you think are gone, your wallet will quickly empty, only change something that has been tested and checked to the book. Remember that all electrical circuits and their components "MUST" be tested under load, especially the start circuitry and its components.

Should you after testing require to replace the battery consider a "Gel" battery over a lead Acid battery, they are by far better suited to ATV's however, do not over charge them and overheat them. Just one full charge once a month up to 14 volts. 

GMSAHFR

My 2019 600 did that a couple of times , I cleaned the kill switch and that took care of it . If it does it move the switch back and forth a couple of times and see if it will start.