800 Trail won't turn over

Started by alkirchhof, November 04, 2021, 04:31:23 PM

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alkirchhof

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alkirchhof
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2021 800 Trail.  Ran fine just last week.  Fuel pump runs, 3\4 tank gas, all lights work, starter does not engage even though cutoff switch in on position (can hear fuel pump), shifter in either N or P.  Just turn key & nothing.  Maybe a fuse?  Help!

doug80638

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doug80638
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So many possibilities.

First check the battery for sufficient voltage. Then check for voltage at the starter solenoid. Make sure all connections are tight on the battery and the solenoid. We've seen new batteries fail in short order, or have loose connections from the dealer, so don't rule those out without testing. Cold temps can bring out electrical gremlins like that.

Jump the starter solenoid to see if the starter will turn over. If it does, put power to the solenoid signal post. If that works,  the solenoid, starter, and battery are  fine.

If you get this far, check for power on the signal wire with the ignition switch in the start position. My guess is there isn't any. All of this should take no more than a few minutes.

If the 2021 wiring is similar to the 2017, the starter relay is on the same fuse as the fuel pump, so the fuse should be good. I don't think it is the ignition switch either since the fuel pump powers up, so look for a loose/bad connection in the harness connectors, or a bad starter relay.

Check the  cut-offs  (gear selector, brake).

The kill switch is a two pole affair, one side powers the EFI circuit (fuel pump, ignition), and the other powers the starter circuit. We've seen may of these switches have one or the other pole fail. Often times the problem can be remedied, at least temporarily, by flipping the switch on and off several times exercising the spring loaded poles to make a good contact.

After that, a dedicated effort to follow the circuit from ignition to the solenoid is needed, including checking the ECU pins for proper signaling. That will take a wiring diagram.

Good luck!
2017 Zforce 800 - Red
SuperATV Flip windshield
Tusk soft rear window
Uni-Filter foam air filter
Bandit springs

alkirchhof

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alkirchhof
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Thanks for the suggestions.  I found, though, the starter and fuel pump are on separate relay circuits.  I found the fuse box, reseated the starter relay module, and it started right up.  Imagine my surprise.

So that was the only problem.  Everything is working fine now.  Just glad it wasn't worse!

Thank you for the help.

Al

doug80638

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doug80638
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Yes, the fuel pump has one relay, and the starter has two auxiliary starter relays that feed the starter relay/solenoid. Makes for some interesting trouble shooting.

Glad it was something simple, but I'm concerned that reseating the relay fixed it (unless it wasn't seated properly). Makes me wonder if there is a weak contact in the fuse box. At least you'll know where to look if it happens again.

The fuel pump and aux relays are on the same fuse on the 2017. I'd be interested in seeing if the 2021 wiring diagram is different.
2017 Zforce 800 - Red
SuperATV Flip windshield
Tusk soft rear window
Uni-Filter foam air filter
Bandit springs