Beerwiser

Use a file, not a grinder if you decide to try to fix the clutches!

Don't bother looking at the CDI yet. That is for spark and if you got no power at the dash so you have to start there. The wife has an 06 so if you need some pictures or whatever I can get them for you. Check all the fuses under the seat and make sure they have continuity. Gear indicator lights and dash should light as soon as the key is turned on, no matter what position the kill switch is in. Also remove the ground cable on the engine case and clean it, it is just below where your gear select rod attaches to the engine(back left).

You can check here for some various manuals Alex, seems you are a lot like me in regards to brands/years lol. https://drive.google.com/drive/folders/1GcqS65GYd3yFmEAGsI7LP-eZp2jMRVJU

As Dave said, pull the plug and oil the top end, but spin it by hand first. I would almost drop the oil too and fill the crank case full of diesel (right to the top of the fill plug) and turn it by hand for a bit. Done that with a few pieces heavy equipment that had "mishaps"

Thanks Dave, it looks like the starter solenoid supplies power to the key. Gonna have to check into that.

Bondo won't work at all, the vibrations alone will cause it to break off. Then you got temperature changes to deal with too. With the inside of the case, I wouldn't get to carried away there unless you need to repair critical areas. Looks like a bit around the bottom and to the right of the oil pipe could use some attention and right below that on the lip of the case is all I would worry about. Have you had it running yet should have been my first question. I would fire it up with the clutches off to see if there is even a reason to move ahead since it almost looks like it was sitting in water up to the crank.

This where I am lost. The neutral safety and reverse works when the quad is running along with shutting the quad off with the key. Turn the key on with the engine not running and there is zero power to anything. The quad does not charge the battery either. There is what looks like a junction box mounted under the handle bars to the frame, do you happen to know what is in there?

Wow, I have never seen anything that bad before. You need a bit more than sandpaper unfortunately. I would actually be worried about the integrity of them particularly the secondary. Personally I would replace that secondary, that missing chunk on the 3rd last picture is in a bad spot. You might be able to salvage the primary with jb weld, but then you get into balance issues and how long it will actually last. Build it back up with a TIG would what I would on the big area on the primary in the second last picture. Build up the main area, grind off any high spots and jb weld the smaller low spots. Still have to be careful on the balance. It will take some time to build it up with TIG, but it will last. How did it get that bad? Salt water or something?

So I bought this fourtrax a few years ago. Put a new battery in and all was great. A couple of months later I lost all dash lights when I turn the key on and the start button doesn't do anything either. I can still start it and run it off the kick starter and the neutral an reverse light will work, but you can tell they are running off the stator. Battery connections are all good and electrically closing the starter solenoid will engage the starter and start the quad. I don't see any physical damage to any wiring off the handle bars/key area. Does anyone know where to go from here? I am getting too old to use the kick starter.

Yeah, photos are always best. I completely get the money part, I am cheap as cheap can be lol.

How bad are the pits? I have run sandpaper over primary and secondary's on sleds to get it relatively smooth. I think I was at 1000 grit when done. As far as coatings, I don't know of any that would work well, but JB weld would work if you have deep pits. Belt, buy a new one after you run the old one a bit to get the clutches shined up. Broken belts in the bush suck.

Found this site by accident, wow there is a ton of info here! I am just a farmer from east central Alberta looking to find what the largest width of tire that fits on the front of a 06 kodiak. The 25x8x12 suck as that quad is sort of front heavy. Cheers🍻 Ted