2015 trx420 es starter problems - Honda ATV Forum
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post #1 of 12 (permalink) Old 07-01-2019, 01:38 PM Thread Starter
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2015 trx420 es starter problems

the relay just clicks and won't start. when I put a test light on the relay with key off the light comes on. seems to me that should only happen when the starter switch is pushed.
am I wrong?
thx
bob
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post #2 of 12 (permalink) Old 07-01-2019, 10:16 PM
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Depends on which post you touch your test light on. The battery cable side is always hot. The starter cable side is hot only while the starter button is depressed.

Apply positive battery voltage directly to the positive post on the starter motor to test that. If it runs replace the solenoid with an OEM Honda part only. If the starter won't run while jumpered directly, replace it with OEM. Don't buy any china knockoffs parts for it unless you are very wealthy.
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post #3 of 12 (permalink) Old 07-02-2019, 12:09 PM Thread Starter
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relay is hot even when starter button is not pressed using a continuity light.
the only wire I can find going to the starter is the ground side from the relay. is that the positive terminal for the starter?
when I touch the starter terminal with a lead from the pos battery side I get nothing.

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post #4 of 12 (permalink) Old 07-02-2019, 12:46 PM
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Thats wrong, you really need to download a copy of the service manual (and read it!) to work on Honda ATVs.

https://www.hondaatvforums.net/forum...downloads.html

Here are two stickys that should help ya get everything connected up right:

https://www.hondaatvforums.net/forum...s-battery.html

https://www.hondaatvforums.net/forum...oise-read.html


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post #5 of 12 (permalink) Old 07-02-2019, 02:37 PM Thread Starter
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i didn't hook it up the way it is, it's factory . looked at your diagram, problem is there is only one wire from the relay to the battery and the engine is the ground for the starter.
anyone have a clue as to why there is electricity going thru a relay that should only have electricity when the starter button is pushed.
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post #6 of 12 (permalink) Old 07-02-2019, 08:42 PM
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If yours is hooked up right and if I'm reading your explanation right, then your solenoid is stuck. A new OEM Honda solenoid will be needed in that case.


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post #7 of 12 (permalink) Old 07-02-2019, 10:01 PM Thread Starter
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logical but why does it still click if it's stuck? the continuity light will still come on even with the key in the off position.
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post #8 of 12 (permalink) Old 07-02-2019, 10:29 PM
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I don't answer why questions. :-)

Seriously though, if your bike is wired up right and you are seeing battery voltage on both of the large solenoid terminals at all times, then the solenoid is junk. Has it been replaced with a china solenoid? That would explain everything! :-)


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post #9 of 12 (permalink) Old 07-02-2019, 10:41 PM Thread Starter
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numbers indicate oem part, I agree it's junk. may be a cascade effect as I wasn't able to kimp from the battery to the starter either.
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post #10 of 12 (permalink) Old 07-02-2019, 10:51 PM
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Solenoid design 101

Once you replace that solenoid with an OEM Honda part number, break the bad solenoid open with a 3 lb hammer and you'll find that the contactor has arced heavily and has welded itself to the two large terminal posts. You'll also see that the electromagnetic plunger is designed with a loosely sliding attachment to the contactor washer that is stuck/welded to the two posts. That attachment may have broken due to the arcing heat. That loosely sliding plunger attachment (or broken attachment in some cases) is the source of the "click" noise that all stuck solenoids produce. In other words, they can click even if they're stuck because that loose attachment allows a limited, but free movement of the plunger. The magnetic force acting on the plunger is very strong but is uni-directional. Unfortunately there is only a light spring inside returning that plunger.


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