2004 Arctic Cat 400 TRV Won't Start

[alexwv1863]

I can't remember if I posted about this last year or not, so if I did, I'm really sorry. I have been working on a 04 Arctic Cat 400 TRV (Automatic, green) and I cannot for the life of me get it to run. Now, I do know it runs because I had it running for a few minutes after I first started working on it last year. The issue it had at that moment was it would idle but every time you'd give it throttle, it would die. My dad was helping me by starting it. Well, it ended up getting hot and wouldn't start. One of the magnets in the starter broke. I thought that was the problem, but it wasn't. So far I have replaced the starter, carb, flywheel, stator, fuel pump, rectifier, handlebar control switch, ignition coil, starter relay solenoid. I think that's all. A friend of his said he needed to replace the shift sensor. I couldn't figure out where it was located. I do have an idea, but I haven't looked to make sure yet. I was working on someone else's 4 wheeler. This Arctic Cat has me at my wits end honestly. I do have a manual downloaded. If anyone has any ideas, go ahead and leave em. I'll let you know if I've already tried it yet or not. I really hope to get it running this year and out of my hair. I don't want to ever work on it again. 

[alexwv1863]

I said the wrong sensor. It wasn't the shift sensor he was told that needed replaced. It was the crank sensor. I can't find anything called a crank sensor. So, what else could it be called? 

[davefrombc]

He likely meant the pick up  coil . it's what  mounted inside the stator  and picks up the pulse from the flywheel magnets

[Curtis Underwood]

Well first thing first 😂. Lets start with standard troubleshooting.
1. Make sure battery is fully charged. 
2. Drain the fuel and put new fuel in since it has been a year since you worked on it. Drain the carburetor. Fill with new fuel.
3. Check to see if it is firing by removing plug and turning it over. If it is not firing goto step 11 and if it is firing goto step 4.
4. Remove air filter and use 1 sec burst of starting fluid while turning over. If it ran for few seconds you have carburetor issues goto step 5.
5. Remove fuel line from carb use a cup to catch fuel and turn engine over to see if fuel is flowing (most artic cats have fuel pumps). If fuel is flowing goto step 9
6. Remove input line from fuel filter and turn engine over if you have fuel flow replace filter.
7. Remove fuel line that runs from tank to fuel pump. Lay the fuel hose lower than tank or use a hand pump to see if you have fuel flowing from tank(if you do it is a problem with the fuel pump).
8. The fuel pump on most of these use crankcase pressure changes to pump, if fuel pump hose to crank case is good and you turn the engine over with the tank line hooked up and no fuel flow out of the carb line then either one of two things is wrong you have a bad crankcase pressure leak or the fuel pump is bad. Replace pump and recheck.
9. Clean carburetor by removing caburetor, remove bowl, remove jets (use torch tip cleaners to clean jets out), Spray all ports and tubes with cleaner(Best to use a tank cleaner and let soak then use water to wash carb and blow out with air).
10. Put carb back together and try if it runs great but if not replace carburetor.
11. Not firing. This area get complex due to the CDI module has a lot of inputs and outputs that have to have the correct voltage for it to run. Below is a wiring diagram for a 400 Artic cat. Item 11 is the CDI module that controls the firing, Item 16 is the magneto and firing sensor, item 10 is the coil. As you can see it is complex. I could not find a decent diagram without purchasing the manual. But below is a diagram but not very readable.
So if it is not firing we will have to work you throught it.

 

[alexwv1863]

I probably won't get to work on it until Saturday. I'll need to start over since it's been months that I've worked on it. I don't have a garage, so when it started getting cold, I put the tools up and closed shop. Lol. When weather got warm, I had other projects coming in, and honestly I just dreaded starting work on the Arctic Cat. I have two other ATV's I need to work on, so I really need to get this one running and out of my hair. 

I know that when I first started working on it, the starter went out. Im assuming it got too hot from cranking so much on it and that's what broke a magnet. It just snowballed from there. I was trying to find out how to test the cdi box because I was told that since there was a magnet loose on the factory flywheel, it could've caused a short or something and affected the cdi box. I tried another factory cdi box and it kept blowing a fuse. Not sure why. I know very little about electrical wiring and such. I did go through the entire wiring harness and found some wires had bare spots in the wire covering. I taped every one that I found and made sure nothing was being pinched off as well. 

Sorry for the long post. I'll post when I check everything you mentioned Curtis. I really appreciate all of your help and everyone else's as well.