So, I helped my buddy replace the stator in his 700. The old one was toast. He bought the bike and it needed some work. It would run great but was not charging.
We ordered all the necessary parts to perform the update to the case to prevent repeated failure. We stayed up until midnight Friday, getting it all back together, to go ride over Memorial day weekend.
It was later in the afternoon when we got out to Crossbar, the sun was beating down and most of the machines were experiencing some overheating issues from the slow pace of riding the rougher trails.
At first it ran great, but bout 45 minutes into the trail it tried to overheat. The fan wasnt coming on. After a quick inspection We found a bad cooling fan relay. Luckily we had a spare and swapped it back in. After we got the fan to run and let it cool of it would start die, start die. We towed it back to camp and started looking it over and double checking out work from the night before.
We got it into diagnostics mode and at first it was throwing a plethora of codes. There were 7 codes (I believe these were the majority) One was the tip sensor, primary coil resistance, unstable battery voltage, crank sensor circuit, and one more that I dont recall. Codes 8, 12, 30, 33, 46.
I believe there was either a code 15 or 17, probably irrelevant as the only code that continues to come back after we cleared them is 12. I concluded that most of those codes were thrown when the stator failed and he had to jump it.
I started with the coil. We checked the connections. Replaced the boot, new plug. The way it is acting I assumed bad coil. It fires right up after sitting, once it reaches operating temp it dies. This is a classic sign of a bad ignition coil. It will do this repeatedly like clock work. We double check the oil level. It was just below the full line so we added another 1/2 quart just to be safe.
Im assuming most of these were due to low voltage before the stator swap. After clearing the codes we are left with a crank no start issue code 12 and before anyone asks yes it is cranking over. I have found other threads where bad relay or bad starter throws the code. This isnt the case. The motor is turning over, I am either not receiving a reference signal from the crank sensor OR ___________ fill in the blank.
Here is the kicker. If you let it sit it will start and run until it gets to operating temperature and then it dies. It just dies as if you were pushing the kill switch.
Ive also found another strange twist. WHEN it starts after sitting, and you place it in four wheel AND in gear it dies immediately.
We found this out while trying to unload it off the trailer. It will repeat this every single time. If you place it in four wheel drive and leave it in park it will stay idling.
I have checked the connections, check the wiring its all still good. At first I thought it was a bad stator assembly/crank sensor, but the fact that I can get it to repeatedly die while putting it in gear AND in four wheel drive has me stumped.
