Greetings fellow Cat owners. New to this site. I just bought a 06 TBX 400 Auto from the original owners. It has 625 easy miles on it and was never abused at all - it is in near showroom condition. Yesterday was the first time I got it up to operating temp and pulled it into the driveway and shut it off after riding about 3 miles or so. About 15 minutes later I went to re-start it and it would crank over but would not start. I pulled the plug and found no spark. Checked all fuses, relays and diodes and everything else that could be obvious, but to no avail. Everything else works - lights, winch ect. - it just will not spark. No obvious noises and ran flawless before this happened. Short of bring it into the nearest dealership (100 miles from us) I dont know what to else to do. Is this a common occurance? I sure hope it is something stupid that I'm overlooking. Any help would be very much appreciated. Ron

 

check the kill switch, I've done that be for lol

 

We've looked at that already, however, without the red kill switch in the 'on' position the engine will not crank over. So, at this point we've done more troubleshooting. I've did the coil resistance test (.4 ohms verifiied) and also verified voltage (310 Volts DC) at the white wire with blue tracer leading to the coil from the CDI box. Appears the coil is ok -looking at the resistance test- but seems there's voltage going to it which tells me a resistance test may not be a good enough indicator to rule it out as the problem. Any more input would be a big help.

 

Did some more troubleshooting tonight. Here's a few more items I've checked:

1) Ignition switch plug (lower) - Verified 12V at the red wire in the 3 pin plug next to the steering post.
2) Ignition switch plug upper restance test - .3 ohms @orange and gray wire with ignition key on.
3) Coil secondary winding resistance test with spark cap off - 7.15K ohms
4) Spark Cap itself resistance test (9.61K ohms)
4) Coil primary resistance - from 1 terminal to the other - .3 ohms
5) Re-checked peak voltage at the white and blue tracer wire leading up to the coil coming from the CDI box - 395V DC (without cranking over)
6) Re-checked all fuses once again (using ohms on the multi meter)

At this point I am stumped. I guess the next step before bringing it to the dealer would be to somehow diagnose the magnito to see if there is something wrong with it. Does anyone know an easy way to troubleshoot it?

 

Have you tried a new, properly gapped spark plug?.

 

No, however, I switched the spark plug into my other AC 250 ATV and it sparks just fine in it.

 

Pull the flywheel, I bet the stator magnets have fallen off. It's a common problem with the 400's, at least you didn't get left on the trail. The Suzuki Eiger 360 flywheel swaps with it, it's a better design; do that and you should be good to go.

 

Before you tear into the flywheel check the electrical plug connections on the wiring harness along the steering column. There is a plug up there that can get that goes to the ignition that can get bound up in a narrow slot between the plastics and the steering column and if you turn too sharp. It unplugs and kills the motor.

I have had this happen to both my AC's after I had cleaned and coated the plug with dielectric grease and after I had the winch installed when they were new. Wires are just too short and there is not much space there.

Swampy

 

Well, I reluctantly took it to the dealer only to have them mis-diagnose the problem as a CDI box. They ordered one from Arctic Cat only to find out that it was NOT the problem. Turns out it was infact loose magnets on the flywheel. Apparently, the factory is going to cover the flywheel under warranty but I must pay for the labor (something completely foreign to me as I've never let anyone work on anything I own). There, however, seems to be a 3 week backorder on the newer style flywheel which puts it way into my hunting time . But, I still have my trusty 2000 250 2x4 which has given me 0 problems and always starts!

 

Check the local Suzuki dealer, theirs are better. The 2000 250 is a Kymco. That's why it runs. LOL