Ok so let me start off saying this is an amazing forum and resource. Even though this is my first post, I've read through many first.
I bought my '04 this past June (2nd owner, still brand new condition, lots of mods but not much on engine side, but can tell wiring was cleaned up probably when apart to powder coat) and now just finally cooling down enough to get on it for longer Glamis rides. It was starting and running fine and just for good health purchased a new battery that was fully charged prior to trip. Last weekend in the hills I parked and when tried to restart no power, no light from neutral either. Popped the seat and noticed the connector for the positive terminal worked itself loose and lost the screw back. I pulled the one from the battery ground and rigged a larger bolt to hold down the ground, but still no power, no crank, nothing. Have a feeling the battery was getting drained while riding even kept the lights on.

Now back home - charged battery full (13.3V) and connected back in. I'm getting the green neutral light again but not starting and making some really scary clicking noises. Put it on the charger and tried to start ensuring better power, still no dice. I also notice that when I turn the handle bar "run" or the key both put a pretty hefty load on and drop the 12V down to the 3-9V range. I recorded a quick video (below) so you get an idea what I'm hearing.. any thoughts, i'm lost...

Could this be as easy as defective battery problem, not holding charge? (especially under load)

Have not tried to jump start again but did in hills with no luck, possible still didn't have good connections and grounds.

http://www.forward-footwear.com-a.googlepages.com/test
quicktime video

Thanks in advance,

Michael

try taking out the screw and holding (with gloves on) it against the terminal. see if it helps, your screw might not be a good conductor.

if that doesnt help id suggest doing a diagnostic check on your wireing. check your solinoid and your relay.

if it has anything to do with starting components this is the way to check. have your quad in 2nd gear pull the clutch in, run as fast as you can with it down hill release the chutch and if it starts, ride it back, and check through all of your starting components.

Thanks - will try. with paddles hard to jump it. Broke down and bought the service guide yesterday and looking over the electrical systems and tests. Will definitely start with the switches and electrical.

Just looking at the multi when all off 12+V, when key on and run on, drops down, is that normal? Or is there a short or something else putting more load than normal on the system? (the video details this)

sounds like you have a bad cell in the battery. I had that happen a few times and when the battery cell is dead you will have a had time jumping it even with a charger on the battery. I would get a nw battery and try that before I started into the wiring. Eliminate the simple things first

Good thought, I can troubleshoot a computer network like a motha, kinda agree and hate to over look unplugged power cords.

It's a brand new battery, but agree could have been on the shelf or undercharged for longer than expected before sold.

true that. if you an get it to jump start that will tell you alot.

this is a alot harder than a jump start, but wraping a rope around your back tire while the quad is on a stand and giving it a solid yank could get your motor to crank over. (2nd gear) if it starts, great!

Update: Battery
Even though this battery is brand new and been on trickle since purchase, I think it's the issue. Multi-M shows full 12.7V but as soon as I put a load (turn switch on & run) if falls well below 12V and has no juice to push the starter. I connected my truck charger with the 50A and after a couple tries, fired right up. I hope its just the battery and not some other mystery runaway load when I add another battery, but for now, i'm going with defective battery or cell in battery.

Thanks again for the help and input.

Thats one nice machine you got there. Clean too, also love the few peices of chrome! Bet you gotta wear some shades when looking at that in the bright sun!

Hey dude I have the same problem new battery so wat should I do man I want to ride. ....?

Thanks, I was fortunate enough to buy it this way. all work and mods were done buy the original owner who was in the industry and spared no expenses on this, "his wife's bike"