mikeexplorer

Good to hear

Rebuild, you can get a brush kit from rick's motorsports. I had to do this on my 2007 400, if I remember right, it was like $35? (this was a few years ago)

https://ricksmotorsportelectrics.com/?gclid=EAIaIQobChMInYrsxfCr6wIVNxatBh23-AgLEAAYAyAAEgJYk_D_BwE

The service manual gives you the specs for what the voltage should be at the primary side of the coil, but you need a meter that can record peak voltage to see it.

It must be in range since you are seeing spark. Make sure its a strong spark.

Yes the starter may be spinning slower under load if the brushes are wearing out, but check connections and clean them since any corrosion will cause the same thing.

Mike

I meant to measure the peak voltage the primary side of the coil is getting. On my 366 which would be similar it is around 375 volts.

Starting to look like the CDI may be bad if your only seeing battery voltage

Now you need to look at the schematic. I attached it. The position sensor's output is routed into the CDI box, out of that it goes to the coil to produce the spark.

The actual output from the sensor might not be the issue, it is a trigger signal to the CDI to produce an output voltage to the coil. If I remember right, its around 350 volts. (your service manual will tell you this) I was troubleshooting a 2010 366 two weeks ago for hard starting issues and remember testing the coil.

You need to be able to first measure the position sensor's output when your cranking and when it finally starts, does the voltage change?

Next, check the primary side of the coil, the procedure is in the manual as well, but you need a meter that can record the peak voltage since its not a constant output.

You need to see if the output from the CDI is changing when your cranking to when it finally catches and starts.

Although you said you have a new battery, I would have it load tested to verify, places like Autozone will do it for free.  As a quick test, connect jumper cables from your quads battery to a vehicle battery BUT DO NOT START THE VEHICLE! Then try to start the quad. The increased cold crank amps will tell you if its the battery.

On a side not, check battery connections and such for corrosion. Since its an older machine, going over the connections and cleaning them and adding some dielectric grease would be a good idea, voltage could be dipping down due to resistance caused by corrosion. EFI machines are finicky when it comes to voltage. 

You can get some electronic contact cleaner spray and dielectric grease at any auto parts store.

Mike

When you replaced the coil, did you buy the whole unit (including the spark plug cap?) or just the coil? I would measure the resistance of the cap only. You mentioned a 20K reading which is high for the coil, but if your including the cap, that will throw the reading off.

Your attachments were too small to read. Looks like your stator is outputting as it should. I would check the regulator. Once the machine is started, check the voltage to make sure it does not exceed 15 volts. High voltage will cause EFI machines to act weird.

I have not known of issues with the stator and position sensors. One test you can do is when it does not want to start, pull the spark plug and verify you do indeed are getting spark.

Another thing to check is your fuel pump, make sure you have enough PSI for the injector. Since your machine is older, I would suspect the fuel pump is not providing enough PSI for the injector to work.

Mike

I modified it before even using it. The pump that comes with it uses 4 D batteries, but to turn it off and on is the stupid little red button on the box. Plus the base of the pump won't fit in the jug. So I bought a sprayer pump with the lowest flow rate (1.2 gal/min) and turned down the pressure sensor to a low pressure, then added a ball valve inline to the shower head so when you turn off the water, the pump shuts off. Power for the pump comes from the battery mounted on the Jumping Jack using the 2 pin trailer wires.

The tent was designed for a shower bag only so I zip tied a clip to the shower head and just hang it from the hook.

Mike

A camping option, portable shower. Used this for the first time last weekend and it worked well.

Mike

Snow Shoe Rails to Trails held their annual chicken BBQ event. Food sold out in one hour! (400 dinners) They had a drive through option for those who were not riding.  Weather was warm, but cooled off decently at night. Was good to finally get out camping and riding.

Mike

Welcome back

Happy 4th of July

It may only need a top end, if it sucked in dust it ruined the rings. I had this happen to my 2007. The later years with it since it had high miles it needed to be bored. Ran great after that and I sold the machine.

Mike

Do you hear the solenoid engage (click) when pressing the starter button?

Mike

Is the sound coming from the starter solenoid?

Mike

PA is slowly opening up. DCNR opened the state trails a few days early to avoid a Memorial Day weekend crowd. I have been out riding a few times so far, but our camping trips up to this point were canceled. For the most part I worked, only had a few days shutdown twice, but we were paid for it.

Mike

You notice how most of the scams are Gmail addresses?

I actually never use craigslist, too riddled with scams and people fishing for information.

Mike

Either way, since I had thin pliers, i tapped both at the same time. (make sure your going from the 12 volt wire to center wire.

If it doesn't do anything, I would suspect the wire first. This quad did have a wire harness problem in the front side. It was intermittently blowing the ignition fuse and I found a rubbed through wire in the front frame. If you have a schematic, you can disconnect the pod and verify continuity between the speed sensor plug and the pod.

Its possible the connector to the pod is dirty and not making a good connection. I would suspect a pod problem last.

Mike

We had a chance for a quick ride on Friday at the local state trail before the rain came in.

I have heard of that one about it being handled through "Ebay Motors" and such. I came across one of those "great deals" years ago and got a similar line of bull.

I told them I only do Paypal through Ebay so if they had the Ebay transaction number. Poof! never heard back

I do not know if this information will be accurate for you but last year I had a problem with my Arctic Cat 366 which is basically a Kymco MXU 375. There is a speed sensor that sends pulses to the POD to measure speed. (Picture 1) I had the same problem, reading zero. First picture is what the speed sensor looks like ON MY QUAD. It MAY be the same on yours?

First thing to do is unplug it, clean it with electroclean (you can find it at any auto parts store) then measure with the ignition on to verify it has power to the sensor.  (picture 3)

I have a meter that can measure Hz and I was able to verify the speed sensor was bad with it quickly. There is another way. Look at Picture 2. With the ignition on take a thin pair of needle nose pliers or use a piece of small gauge wire and go from the +12V lead to the center lead and "tap" it several times. This will simulate the pulses sent by the sensor. If you POD shows a speed reading, the sensor is bad. If it does not. You may have a broken wire or a bad connection to the POD, or a bad POD.

(My meter showed me with the quad running at idle, I had pulses coming from the sensor, but the voltage output was too low for the pod to read)

Mike

Look at this.

https://www.mobilityquad.com/

Sorry to hear, hope things work out for you.

Here is a list of error codes and how to display them with the diagnostic plug.

Mike

AC Error Codes.pdf

Nice pictures!

I think the 700's at that time were the H1 engine, smaller ones such as the 400 were Suzuki. I know my 2007 400 was Suzuki motor

Mike