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Hi I am new to this forum although I am a member of other quad bike forums,
I am a Mechanic here in country Western Australia, Working on all makes of quads,chainsaws etc,recently had a Kawasaki 360 workhorse in my workshop symptons were irregular starting ,it would start 5 or 6 times and the seventh time the solenoid would click,
New battery ,tested the solenoid all good 12.7 volts to starter motor,removed the starter motor ,reconnected the start wire earth the body and press start ,the starter would turn ,all good, I then thought that maybe a mechanical issue so I removed the starter housing and the generator housing ,checked the sprag gear and the primary start gear,no sign of damage no metal filings when I drained the oil,OK,back to the starter motor ,stripped it down and the brushes were worn but serviceable ,tested the armature and guess what, there was a dead spot on the armature, it only became evident if the starter motor stopped at the "wrong Spot.
This may help some out there that experience this problem.
Stay safe and happy biking.
 

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