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Sounds like you have a wire that is ALMOST broken or the insulation is worn off and grounding, or turning is pulling a wire loose from a connection. .. this type of problem is HARD to trace down sometimes... good luck
Hi, Chip this flow chart is for a Harley but the procedure is still the same, it should be noted that in order to "PROPERLY" diagnosis any electric starter issue it is "IMPERATIVE" that you begin with a fully charged battery 12.5 volts or better and be able to pass a proper load test if necessary, and the usual suspects are:
1. Battery terminals have loose or corroded connections.
2. Battery cables faulty due corroded or broken internal wiring at the cable connector especially the "NEGATIVE" cable which needs to be checked at "BOTH" ends.
3. Battery voltage, 12.5 volts or better,to the main circuit breaker to the ignition switch to the security/ignition fuse to the TSM/TSSM module to the engine stop/run switch to the starter button to the starter relay to the green wire that connects to the starter solenoid has dropped more than 1/2 volt.
4. With a voltmeter connected to the battery, the ignition switch in the on position, the kill switch in the run position, the starter button depressed, starter engagement should not bring voltage below 8-9 volts.
If a lower voltage is produced a proper battery load test should be performed with a load tester to validate battery integrity or battery replacement.
5. Faulty starter relay, check continuity.
6. Faulty starter solenoid, check contact plate and shoes for excessive electrical erosion/etching, refurbish as necessary or invert contact plate and use the virgin backside. Check contact shoes for being loose. Replace solenoid if the negative function is still a final outcome.
7. Faulty starter, bench test starter with a 12-volt battery if negative function check, decontaminate and undercut armature commutator segments as necessary, check segments with an ohm-meter probe each one and the segment next to it for shorts. Have the armature tested with a growler and field coils, and brush plate with an ohm-meter for opens, shorts or grounds. Replace brushes if less than .438" It is generally cheaper to overhaul/refurbish a starter motor than buy a new one.
For more information about your issue and valuable "FREE" downloads that you will need please visit the websites below. Good luck and have a nice day. Suzuki LT 4WD Quad Runner Starter Repair king quad wont start clicks see what have to say please 1999 suzuki 300 king quad starter won turn over just clicking noise https://www.tradebit.com/filedetail.php/147670434-suzuki-ltf400f-king-quad-pdf-service-repair
to adjust the clutch on suzuki king quad 1999 locate the oil filter on the right side of the bike look for three bolts with a bigger one in the middle of the threethe middle srew will open up a nut and a set screw in the middle loosen the the nut and turn the the adjustment screw while you are in first gear . hope this helps you