I have a 2000 Honda 400ex with some Trail Tech lights mounted on the handle bars. I had 35 watt bulbs in them and replaced them with 75 watt bulbs. The quad ran fine until I tried to use the lights. The quad was off, I turned the lights on (they worked), and tried to start the engine and I saw a small cloud of smoke and then couldn't get it to start. I even tried bump starting it. I still have power but just can't get it started. Any ideas??? I was thinking the stator, but the smoke is throwing me off, not sure you'd see smoke from the stator with the stator located inside the case? I'm not sure though, I'm def no mechanic. Thanks for any input, it's very appreciated!

-Shaun

 

Main fuse maybe? I dunno.

 

What does it do to make you say it still has power?

 

I checked the main fuse and its ok. I can turn the key on and my green neutral light will light up. I also checked the wiring to the lights with a test light to see if they have power and they do. So I have power going, but if I try to start my bike, it doesn't even turn over. Almost like the kill switch is permanently on.

 

That would have been my guess. Mine would pop that fuse because I had a short in the wiring harness which is very common on the 400ex's. Then it would drain the battery.

But the lights won't come on?

Does it click?

If it won't push start it's more than likely not getting power to the plug to provide spark. If you seen smoke I"d think you would be able to smell burnt electronics somewhere. Under the seat by the fuse you'll find the little CDI box. Sniff around and see if you can smell burnt electronics.

 

Not sure if the lights will come on yet. I just got new bulbs but haven't installed them. I checked the wiring that goes to the lights with a test light and the wiring does have power so I would assume that the lights would work. I'm almost wondering if the box on the handle bars (with the start button, kill switch, etc..) is melted on the inside. I took all the plastics off and traced wiring back to the battery and found no signs of a meltdown. A buddy of mine just told me that I should use a battery jumper box to try to start my bike. He says its possible for the battery to have power, but not enough to turn the engine. There is no clicking noise when I try to start it either.

 

can you jump across the solenoid with the keyswitch in the on position? what does that do? that may signify that assumption about your handlebar start/kill button assemblies. you could've smoked one of them wires where it goes below the seat in the chassis somewhere.

 

He is right but, that's why I asked about the clicking. If no clicky and won't push start than the battery would have to be completely dead, but I"m guessing you have something else going on.

I'm not the greatest with the electrical system so can't offer you alot of help unfortunately. I'd say just trace lines and look over components.

Fuse box and cdi under left side of seat. Little box on battery which should click. kill switch as you mentioned. I"d think something would be burnt up if you seen smoke.

 

came across this a while back. scroll to pgs. 37-39 to see if it'll help you. according to the index, it does a lot more.............

http://www.msdpowersports.com/pdf/pn...ng_diagram.pdf

 

I appreciate your guys help!! I'm at work, but I am going to head home on my lunch in a couple hours and see what else I can find out. I'll post any new findings. Thanks again guys!!