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Discussion Starter #1
I picked this up a little over a week ago for 1200. figured since it ran it was well worth it, the carb that was on it was leaking from the overflow. after 2 cleanings and adjustments. it began to leak from the bottom drain instead. but by that point I had a new carb to install, so brand new carb is on, and for some reason the ignition does nothing. no spinning nothing but the click, it does that for a while turning it on and off, playing with wires, then it will decide to start turning over by the button, I got it started 2 of 3 times it cooperated last night and both times it ran like it was choking. and it died with throttle. eventually it just petered out, so I'm not sure what direction(s) to turn now, and the pull start is apparently messed up aswell, nothing when pulled.
 

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Start by cleaning the starter button. Then wire brush all battery, starter and solenoid connections.
Do you have a good battery ? ( load tested)
 

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Discussion Starter #3
first thing we did after trying to jump it, was take the battery and test and slow charge it for a day, it tested at 13 and dropped to a little over 11 on load. When you say clean the starter button do you mean open up the button itself? It does click and the display dims, but it just doesnt do anything else. every so often it will decide to start turning over but it just doesnt seem to want to catch.
 

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Switch could be dirty, starter could be bad, connections not making good contact.
 

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Discussion Starter #5
I'll take that apart when I get home, I do have my concerns about the wiring, the headlight bulbs appear to not work by switch, but are just on when key is on, and they also literally melted out of the headlight lenses.(i plan to just wire up some LED pods up top) they still light up. dangling there with black plastic melted around the bulb, and I'm pretty sure i smelled something burning yesterday when I attempted to start it.
 

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It sounds like you have rubbed wires in the harness. 2006 and 2007 cats were known for that, I had a 2007 400 that had several wiring problems. It would be in the front part of the harness where it crosses over the frame. In the pinned section I posted a topic on how to download and print out the schematic for the machine on several pages and then tape them together to make one large print.



In my case I spliced out the bad sections with new wires, then soldered and shrink wrapped them with marine grade heat shrink tubing. After re-wrapping with electrical tape, I put a layer of spiral wrap over the harness to protect it from rubbing on the frame again and I never had an issue after that.



Mike
 

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Discussion Starter #7
I've been too tired past few days to touch it, but that sounds like a attack method I'm gonna have to follow, were you able to get to everything? or do I need to take the plastic loose and spin it off to the side?
 

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Discussion Starter #8
well. Crankcase is leaking, compression is low. about 80, looks like somebody has been inside the motor before judging from the silicone everywhere, and try as I might, I cant find ANY rebuild kits for this thing, cheap side or expensive, I beleive I may just have to let this thing ride out of my life before it craps on me.
 
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Drfishstick
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