Spark timing and advance is through the cdi. That's what I've been thinking since the first post when you mentioned that it would pop back but wouldn't start.But before I ordered anything on a guess, I'd still eliminate that it could be a mechanical problem by a leak down test. You can generally tell on engine condition by compression testing (which you've done)and also how much suction from the intake manifold from your hand,but the leak down test is more accurate. If it passes a leak down test,you're absolutely sure it's not fuel or carb related,cam timing is still spot on,flywheel key is still intact as you mentioned,then to me it looks like it's down to the cdi module. Expensive part and not something to hap hazzardly throw money at.
Plus for grins and giggles unplug the regulator as a fautly one can at times screw up a cdi module and see if it starts.

 

Sounds like you have this pretty well covered, but I saw a 04 sportsman 700 twin with the same symptoms. Wouldn't fire, and would backfire through the intake.
Ended up being that they made the cam out of some softer metal, and the lobes wore down.
Totally different animal, but maybe something to look into.

 

Never had major problems on the 700 cam lobes except that I did have one that broke at the milled down portion that held the cam sprocket. That was a mess to repair. Most cam problems I had on worn exhaust lobes was on the early 425 and 500 engines before the HO cam came out. Twin cams on the Predator didn't give many problems unless valves were too tight and the shims needing changing. I had several non running ones drug into the shop for this very reason. He said his clearances was ok,110 psi compression and good spark.Plus he said cam timing was correct.If the leak down test showed ok,still could be a cdi problem if the ignition advance was screwed up or a regulator possibly could have screwed up a cdi spark timing. On that you can pull the regulator connector and see if it starts or not. I'm curious to see what he does find out where the problem is..

 

Yuck, that sounds like a job.
I'm also interested to see what he finds out. Hope he gets it soon.

 

WOW, So it has been quite a while, sorry to keep you guys hanging.

You might wanna read back up and refresh yourself. I had a no start and had tried everything.

So the quad got parked and snowmobile season came so my brother and I switched our wrenches over to the sleds to get them tip top for the season.
Anyway here in the Western NY area there isn't hardly any snow, so I decided to pull the Outlaw out from its corner.

For some reason I wanted to believe that the valve lash was off, so I dove in checking and rechecking my measurements again. Everything seemed within spec.

Then I started looking at the timing, because to me it was the next logical issue.

I did a quick google search to refresh myself on the timing setup and came across an older post by OPT with a picture/diagram.

I looked at the picture. And I was at TDC with the dots on the cams at 12 and 9.

Then I noticed something, the lobes on the intake cam were not pointed out like the diagram, rather they were 90degrees advanced. (I wish I took a picture, however I'll overlay a drawing on the diagram). Because the cam was advanced both intake and exhaust were opening at about the same time. So according to my timing by the dots, I did it right. However the Cam was off 90 degrees. So with this new information, I retimed the cam to where it was supposed to be put everything back together and it started up quick, and ran quite.

Now I'm not sure if the gear on the cam spun the key. I inspected really well, and the key is in there and there seems to be no sign of movement. The Cam was EXACTLY 90 degrees off, So what I did was turn the top mark(12oclock) to where the 9oclock dot was supposed to be.

Now I have to rebuild to rear end cause it is clicking bad.


Thanks for all the help guys!

 

Well since you're not the original owner a couple things. Previous owner just screwed the pooch on the cam timing OR the timing chain had jumped teeth from being loose which I really don't think happened or the engine would have grenaded more than likely if it had.. Glad you finally found the problem.

 

Thanks, OPT. It's awesome to have knowledgeable people like yourself helping the folks on this forum. It was all because of another thread where you posted the diagram.

Bought the bike to flip... However, it's growing on me and now I need a better place to ride it.