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If your Dad is good with fixing vehicles, then he probably has a digital multimeter (DMM). If not, you can get a cheap-o for less than $20, then search Google on how to use one. It probably also comes with instructions. If you don't have one or don't want to bother buying one, then forget reading the rest of this, because you can't diagnose electrical problems without a multimeter and knowledge of how to use it.
-Take the DMM and set the dial to measure DC volts. Put the black test lead on the negative battery terminal. Put the red test lead on the positive battery terminal. What does the DMM read in DC volts with the key and all other accessories off? It should be around 12.6 volts. What does it read when the engine is running and the trans in neutral? Should be higher than 12.6 volts, so the charging system can actually charge the battery. Rev the engine up and watch the multimeter to see if the voltage reading changes. It should remain steady. If it fluctuates, you probably have a bad voltage regulator.
-Find the kill switch and disconnect it. Use the wiring diagram to help you. A kill switch with an intermittent short will cause problems like you have described.
-I don't know where the relays are on a Warrior, but let's play devil's advocate here and say that if you have cracked a relay housing, then there's a good chance you hit a tree or something with the ATV pretty hard at one time or another. That means there's a good chance that you have also pinched a wire somewhere against the frame, shorting it out. The vibration from the engine running and vibration from riding around causes the shorted wire to vibrate on and off the frame, causing intermittent running problems.
-"went through a bunch of electircal wires taped some bad 1s that might of been causing problems" You mean you had multiple wires that were damaged? Not good.
-The way to fix electrical problems is by systematically eliminating one section of the wiring harness at a time. Inspect it and check the resistance of each section with your multimeter. If resistance is abnormally high, then there's probably a chafed wire or corrosion on a connector somewhere. Check for loose/corroded connections, especially ground connections.
Sorry to hear your quad is messed up, guy. Electrical problems can be a pain, especially intermittent ones. Use a multimeter to find where the problem is. Poking around here and there and throwing parts at it gets expensive real fast.
Brian
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