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Discussion Starter #1
I have a 2004 Kodiak 450 that has been super reliable. Earlier this year I replaced the carb, and last month it got a new battery. Other than the carb getting gummed up last year I've never had a peep of trouble from this machine.

On a hunt earlier this week it's like the thing fell apart. At the start of the day the machine was idling fast and clicking when I tried to put it in gear. It's never clicked trying to get in gear.

It ran fine on the way to my spot. About an hour and a half later I had to use it to pull a deer out. I turned the key, hit the electric start and it sprang to life. No problems. When I put it in reverse it almost died as I was backing up. I put it in high and it ran just fine.

I drove to the deer and killed the ignition with key. I strapped my cargo down and was ready to go.

When I turned key to start it again, LCD was blank. No power. No lights. No electric start. I've never seen that before.

If I turned the kill switch to "stop", all kinds of lights lit up around the edge of the panel. Very strange, I didn't even know there were lights there.

Battery is brand new so it's not an issue. (It's still got a full charge according to my charger.)

Before I gave up and walked out of the woods I decided to try to pull start it. I figured it wouldn't work, but it did. I got it running. Once the machine started, the LCD screen came back on and the headlights worked.

At this point the ATV was sitting still, but the LCD said I was going 15 MPH.

I drove a few hundred yards to meet some people and left it idling. Then it turned off on it's own.

I had to pull start it every time, the LCD screen would only work after I started it. Electric start doesn't work, pull start only. Fast idle, blinking reverse light, idle dies on it's own at times, dies in reverse, trouble shifting into gears. I have no clue what could be causing this.

I went out and tried to start it today and it won't idle long. It's super cold here (20's), and while I can get it to start with a full choke, it dies pretty quickly after that.

Any thoughts on what I'm dealing with?
 

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Hey...kdak450...Welcome to GC from Wisconsin.

Just a couple weeks ago a guy has similar troubles. Turned out to be a cracked fuse. Might start be checking all the fuses.
 
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Check all fuses for security and good connection....and check battery terminals for clean connections and the terminal bolts are tight. I am suspecting loose battery terminals at this point.
 
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Did you check the fuses with a meter? Sometimes the filament in them will break where you can't see it.
 

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Do all the above, as well check all your grounds, remove the grounds, sand paper to clean shiny metal and a hook back up.
 

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My friend had similar issues with his Kodiak 450 on a recent ride and it turned out to be a bad battery and his was less than a year old. Electrical things will do some wacky stuff when the voltage is low , don't trust a charger have it load tested because all the charger will tell you is it won't accept anymore charge.
 

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Not yet. I've had a weather related delay. I've apparently got an aversion to working on my ATV when the temps are in the teens. :smile2:

I should have a chance to go over it in the next few days. I'll post back when I've got something. Thanks to all!
 

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Any progress?

Sent from my SM-G903W using Tapatalk

I pulled the machine into the garage today and started to poke around on it. All battery connections were clean and tight. All fuses were good.

After checking all that I pull-started it again just to review my symptoms. Machine jumped to life, LCD display lit up, and despite being parked it said I was going 15 MPH.

Next I checked all the wiring up front, under the ignition panel. I couldn't find any problems.

Finally, just out of curiosity I started pushing down on some connections back near where the battery cables enter the small box where the fuses are. There's a small white plastic box with blue and red wires entering it. When I pushed on those wires to see if I could force a better connection the whole thing came to life. All problems are gone. Sometimes I feel like a monkey with a wrench. :grin2:

image-3 by s s, on Flickr

image-2 by s s, on Flickr
 

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I pulled the machine into the garage today and started to poke around on it. All battery connections were clean and tight. All fuses were good.

After checking all that I pull-started it again just to review my symptoms. Machine jumped to life, LCD display lit up, and despite being parked it said I was going 15 MPH.

Next I checked all the wiring up front, under the ignition panel. I couldn't find any problems.

Finally, just out of curiosity I started pushing down on some connections back near where the battery cables enter the small box where the fuses are. There's a small white plastic box with blue and red wires entering it. When I pushed on those wires to see if I could force a better connection the whole thing came to life. All problems are gone. Sometimes I feel like a monkey with a wrench. :grin2:

image-3 by s s, on Flickr

image-2 by s s, on Flickr
Love it! Thanks for getting back to us, and great work troubleshooting!

Sent from my SM-G903W using Tapatalk
 

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Hey..kdak450...To avoid this happen in the future consider pulling that connector apart, clean it with contact clearer, dab some dielectric grease on it and plug it back in.
 

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Hey..kdak450...To avoid this happen in the future consider pulling that connector apart, clean it with contact clearer, dab some dielectric grease on it and plug it back in.
That connector socks! I had to cut the wires back and solder new 0.250" Tabs on the wires, I also used 4 different color heat-shrink so I know which wire goes where! I also jammed it full of dielectric grease. I don't have the connector housing anymore.. I tried and tried to find a replacement but no luck... I did that over 5 years ago and haven't had a problem since.
 
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