Tao 110 Boulder ATV - Clicking Solenoid, No Starter Spin

[GrayGhost]

I have a Tao 110B ATV that has a new starter solenoid and new starter. The solenoid is clicking when I try to start the ATV. The starter also starts to warm up but I can't feel or hear that it's trying to turn. I am able to manually turn the engine through the stator cover. Any thoughts on how to proceed diagnosing? New to ATVs here so if any other info would be helpful please let me know. Huge thanks in advance.

[cheesy]

First, with a multi meter set to 20V DC, check your battery battery voltage with the key off. If it is under 12.5V, stop there and charge the battery and retest.

If it's 12.5v or above(above is better), turn the key on. Check the voltage again. It should not drop more than half a volt. If it does, you have a short somewhere in the system and need to find that.

If that test checks out okay, hit the starter button with the multi meter still on the battery. If the voltage drops below 11.5V and the starter doesn't turn, release the starter button. If the voltage does not recover past 12.5, the battery is toast. If it does, the starter is the problem. Even if it's a new starter.

Below is the armature of the first new starter I bought earlier this year. There were maybe a dozen starts on it. The wiring was not properly secured or potted.
https://i.imgur.com/IeWqcmyl.jpg

[clash 168cc]

Also for a quick test, if you put jumper cables on it and it starts, it's probably the battery is weak or bad.

[GrayGhost]

I have a brand new battery and it is good. Hoping to inspect the starter tomorrow. Thanks!

[dirtbkr188]

you can try to "jump" the solenoid to see if the starter will turn over by using a screwdriver to (briefly) touch the two big poles on the solenoid.

[GrayGhost]

you can try to "jump" the solenoid to see if the starter will turn over by using a screwdriver to (briefly) touch the two big poles on the solenoid.

I did try to jump and that's when I found the starter was warming/heating up, but no movement.

[cheesy]

I did try to jump and that's when I found the starter was warming/heating up, but no movement.

Unfortunately, that's one sign of a starter with an internal short.

[dirtbkr188]

Reasonably-priced two and three-bolt starters can be found right HERE (https://www.vmcchineseparts.com/collections/chinese-atv-starters)

[cheesy]

Yup.

[GrayGhost]

Took the new starter off and something is preventing it from spinning (including when it's off the engine and no chain attached). Put the old starter back on and it's able to crank but now I don't have spark at the spark plug. Going to start doing readings of the wiring harness and components to hopefully find what's going on there now.

[GrayGhost]

Also found the guy I bought the atv from had the wrong spark plug - this fixed the spark plug issue. Now back to the starter - I get a horrible grinding/vibrating noise when trying to start the atv with the old starter. If I touch the starter with my hand, that feels like the source of the grinding sound. The new starter still won't turn the engine, just a clicking sound. I tried swapping out the new armature with the old starter housing and it resulted in a clicking sound as well.

[dirtbkr188]

Try attaching a red wire from the battery to the new starter terminal, and a black wire from the battery. Holding the starter firmly in your hand, briefly touch the black wire to the starter housing, and the starter should turn, in your hand. That indicates the new starter is good if it turns while you're holding it.


One other thing, try jumping the solenoid with the new starter in place on the engine, and see if it turns the engine over then. If it doesn't, I'll still suspect your new battery isn't putting out at 100% and may be bad.

[GWD]

I need to replace the Rack and Pinion Unit on my grandson's TAO GK110 Go Kart.
Before I buy one, I would like to see a video or instructions on how to complete the repair. Can anyone provide instructions or point me toward where to go to see a video or instructions?
Any help will be appreciated. Thanks in advance.

[david3921]

I need to replace the Rack and Pinion Unit on my grandson's TAO GK110 Go Kart.
Before I buy one, I would like to see a video or instructions on how to complete the repair. Can anyone provide instructions or point me toward where to go to see a video or instructions?
Any help will be appreciated. Thanks in advance.

You'll probably get a better response if you start your own thread.

[GWD]

thank you... new to forums!!!!