FIrst off using a jump box to supply power which I have used to jump my other two buggies as a test to rule out.
When I turn on the jump box and move the key to on (but not start all the way to the right) the lights function the relay in the dash clicks on
I have circumvented/bridged the brake sensor.
when I move the ignition to the far right to turn over the engine I hear the solenoid click once or rapidly. I can feel it actuating.
When I apply direct power to the electric starter motor the positive wire gets very hot quickly. The Negative I have clamped to the bolt frame stays room temp. The starter motor does not turn
If I remove the starter motor and apply current it spins freely and seemingly very strongly the teeth look to be solid and un-marred.
If I bridge the solenoid gap the starter shows no movement and the pliers turn red hot WAY faster (instantly) than my 150cc buggies would.
How should I proceed?
I am open to replies here or if anyone wants to chat on skype or the phone that can be arranged.
Thanks in advance.
_________________ 150cc Roketa GK-28A Sold ($900) 110cc something SOLDARINO ($350) 150cc carter Talon DLX II (sold 4/10/2016 $1100) 150cc Tomberlin Crossfire 150R (sold $800 3/4/16) 250cc Explorer something 250cc Baja DN-250
Post subject: Re: 250cc "explorer" Clicking on ignition toggle. No turn o
Posted: Thu Mar 03, 2016 3:41 pm
Admin
Joined: Wed Nov 28, 2007 2:21 am Posts: 18108 Images: 24 Location: Pacific NW
Turn over the engine by hand at the variator to make sure it is not seized. If you can spin the engine, the starter is weak/bad. If the engine is frozen, more tear down is needed.
Post subject: Re: 250cc "explorer" Clicking on ignition toggle. No turn o
Posted: Thu Mar 03, 2016 4:56 pm
Admin
Joined: Wed Nov 28, 2007 2:21 am Posts: 18108 Images: 24 Location: Pacific NW
Try the same with the spark plug removed. If gas was running into the cylinder, it may be hydro locked. If it still does not turn, it is time to pull the head and see if it just needs a piston and cylinder or if it is worse due to a failed valve.
Got it all tore down piston had watery gas in a pool on top of it. Some minor rust. I hate idiots who cant care for things and lets them just rot in the back yard. Should have a new gasket set in the mail in the next few days then I will get it all put back together.
_________________ 150cc Roketa GK-28A Sold ($900) 110cc something SOLDARINO ($350) 150cc carter Talon DLX II (sold 4/10/2016 $1100) 150cc Tomberlin Crossfire 150R (sold $800 3/4/16) 250cc Explorer something 250cc Baja DN-250
Post subject: Re: 250cc "explorer" Clicking on ignition toggle. No turn o
Posted: Thu Apr 07, 2016 1:05 pm
Initiated
Joined: Thu Mar 10, 2016 4:44 pm Posts: 56 Location: Royse City, TX
I am actually excited to see another user with the 2005 Joyner Explorer. I too am restoring one that was left for dead at my uncles. It needs a lot of TLC and hopefully I can pick your brain over time to ask questions. Specifically about the wiring. I will attach a couple pictures and if it's ok I will reach out for help on questions I may have.
Attachments:
WP_20151024_002.jpg [ 1.63 MiB | Viewed 3835 times ]
WP_20151024_008.jpg [ 2.11 MiB | Viewed 3835 times ]
WP_20151121_006.jpg [ 2.35 MiB | Viewed 3835 times ]
Greetings I just saw your post! it's nice to hear from you! It is night time here I will look at my buggy tomorrow morning and send you over what I can and take lots of photos with circles and arrows and paragraphs on the back of each one to be used as evidence
_________________ 150cc Roketa GK-28A Sold ($900) 110cc something SOLDARINO ($350) 150cc carter Talon DLX II (sold 4/10/2016 $1100) 150cc Tomberlin Crossfire 150R (sold $800 3/4/16) 250cc Explorer something 250cc Baja DN-250
Post subject: Re: 250cc "explorer" Clicking on ignition toggle. No turn o
Posted: Mon Apr 11, 2016 5:46 pm
Initiated
Joined: Thu Mar 10, 2016 4:44 pm Posts: 56 Location: Royse City, TX
Well we had a good weekend, got quite a bit of the wiring figured out and got the ATV to start but not truly run on it's own. It's a step in the right direction. Mud dauber's built quite a nest in the belt cover. We had to take the cover off to clean out the nest that had almost completely plugged the main opening. In doing so my nephew broke the two top bolts that hold the cover onto the block. Looks like I will be drilling those out and putting a nut and bolt combination to hold it on. But it did run, it won't run on it's own yet but it did start up. That's a step in the right direction. I did not find any connection on the carb for the filler neck hose nor did I find one for that plugged hose coming off the block in the above picture. Also noticed what appears to be a tube near the back of the Belt Cover on the Block that I have no idea what it's for.
I was excited to get it to the point where the new starter button is working and it turned over and ran with us spraying starting fluid directly into the carb. Still might be something wrong with the fuel delivery and the vacuum hose configuration. Looking forward to working on it again next weekend.
Well we had a good weekend, got quite a bit of the wiring figured out and got the ATV to start but not truly run on it's own. It's a step in the right direction. Mud dauber's built quite a nest in the belt cover. We had to take the cover off to clean out the nest that had almost completely plugged the main opening. In doing so my nephew broke the two top bolts that hold the cover onto the block. Looks like I will be drilling those out and putting a nut and bolt combination to hold it on. But it did run, it won't run on it's own yet but it did start up. That's a step in the right direction. I did not find any connection on the carb for the filler neck hose nor did I find one for that plugged hose coming off the block in the above picture. Also noticed what appears to be a tube near the back of the Belt Cover on the Block that I have no idea what it's for.
I was excited to get it to the point where the new starter button is working and it turned over and ran with us spraying starting fluid directly into the carb. Still might be something wrong with the fuel delivery and the vacuum hose configuration. Looking forward to working on it again next weekend.
that hose off the CVT case (belt cover) is a breather let it hang out loose. while you are in there change the CVT gear oil its the small bolts to the aft of the case
Attachments:
File comment: note the bolt on the far right on slightly behind the clutch. that is the fill the one lower and obstructed in this image is the CVT drain I use Gear Lube 75W-90 PICT2207.jpg [ 103.42 KiB | Viewed 3751 times ]
File comment: Take note of the top and bottom hoses this is a proper coolant overflow tank from an atv I had to buy one the previous rectal aperture who owned mine broke it and was using a 10w-30 oil bottle.
the top line goes to the top of your radiator the bottom line goes to that pesky line I was stuck on coming off the upper thermostat hose line that i had dumping coolant like the hooverdam gone awry
s-l500.jpg [ 30.38 KiB | Viewed 3751 times ]
_________________ 150cc Roketa GK-28A Sold ($900) 110cc something SOLDARINO ($350) 150cc carter Talon DLX II (sold 4/10/2016 $1100) 150cc Tomberlin Crossfire 150R (sold $800 3/4/16) 250cc Explorer something 250cc Baja DN-250
Post subject: Re: 250cc "explorer" Clicking on ignition toggle. No turn o
Posted: Wed Apr 13, 2016 12:23 pm
Initiated
Joined: Thu Mar 10, 2016 4:44 pm Posts: 56 Location: Royse City, TX
I agree that I need to change that fluid out. I took that bolt out and did notice it draining a white milky oil. Hopefully it's not a blown head gasket. As for the Overflow bottle, if I am not mistaken mine only has a single hose from the Filler Neck. I will have to take a closer look. I do now know that my Thermostat has a hose coming out of the top of it (small) that goes into the carb, then another line just below that that goes to the 3rd connection on the Filler Neck.
I am attaching an owners manual for the 250cc Joyner Buggy from 2009, according to Joyner USA the engine and wiring specs are very similar with obvious exceptions.
{Edit} won't let me attach the file, too large. http://joyner-usa.com/manuals/ I downloaded all the 250CC manuals for cross reference. They help.
Post subject: Re: 250cc "explorer" Clicking on ignition toggle. No turn o
Posted: Wed Apr 13, 2016 12:47 pm
Initiated
Joined: Thu Mar 10, 2016 4:44 pm Posts: 56 Location: Royse City, TX
I started a new thread for the JN250DA. Hopefully it will give the few of us that still have them a spot to share information on this dying breed of Joyner ATV's.
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