I have a 01 400ex and am having problems with the electrical, starting in particular. The bike starts and runs fine, but i have to arc it accross the cylonoid. The start button dosen't work, and the lights don't work. The ignition key functions properly, because it's how i kill the engine. I have traced the wires and not found anything loose, even metered some of them to make sure they wern't damaged. This started after we went on a ride in Mena, AR. It ran fine for the trip, loaded up fine, then when i went to take it off the trailer at home it didn't work. Couple of weeks later i tried it, and it worked. We went riding in Pitkin, LA and it did fine till the end of the ride. I was sitting next to a water hole, watching some of the guys play, tried to start it, and now i am back in the same boat. I don't know if there is a short somewhere or if the cdi box is out or just what is the problem. I am thinking of buying a completely new wireing harness, but don't know if that will fix it or not.
thanks
Jonathan

 

thast woudl be expensive and even more time consuming. u might want to start by cleaning the start buton and light switch, both of mine were realy bad when i pulled it apart, especially the lights, they wern't working at all, and my start button i had to "roll" around to get it to catch. after cleaning it. works like a champ. i recomnd doing this before you go throght the rewriring of the whole quad. my .02

mk3 bowser

 

You might want to look at the neutral/reverse switch if it has reverse. You also might want to look at the wiring to the clutch lever as this has to be pulled in if it is in any gear but neutral. Now with that said, being an ex auto-electrician and industrial electrician, I would get a 12 volt test light and put it on the wire that energizes the solenoid and push the start button to see if you are getting power to the solenoid(trans in neutral). If you are the problem is the solenoid, if not you need to go to the next componet in the system and check incoming and outgoing power to determine if that item is the problem. Hope this helps you out some.

 

I already replaced the light switch assembly and that didn't work. I will try your idea with testing all the components down the line. But i will have to wait till it breaks again. Right after i made my post on friday, i went outside and loaded it up in my truck, and low and behold, it works now. Crazy huh? Thanks for all your help.
Jonathan