Finally, after months of waiting, my fixit guy seems to have found the gremlins in my 2012 Magnum, and I drove it home yesterday with no problems. I now have to put all the plastics and seats back on, then do some Bondo work on one fender, but one thing remains. The speedometer doesn't work. It lights up but doesn't register mph or miles on the odometer, which it did before all this other stuff. I can live with that and just pace myself by the other traffic and guess at the mileage, but would prefer to fix it and frankly am not sure how it is supposed to work. Looking at the speedo itself and the relevant page of the service manual, it appears to connect to a gizmo on the front wheel that is MECHANICAL rather than electrical -- an old-fashioned speedo cable, not an electrical sensor. The speed display itself is an LED display in the dashboard, but I think the odometer is still a mechanical unit with the little rotating wheels -- not completely sure about that. This is probably not a Magnum-specific question, I imagine most speedos are pretty much alike, so anybody out there who has worked on this particular device, advice welcome.
My speedo is integrated into the dash with several other things -- temp gauge, fuel gauge, idiot lights -- and there are about a zillion electrical wires running into the back of it. Plus, I assume, an old-fashioned speedo cable I haven't even seen yet at the upper (dashboard) end. So not sure how I could replace all that with something from TrailTech. It's a thought though, will keep it on my back burner while I await other feedback.
Is that an actual electric sensor down by the front wheel? Shop manual makes it look like a mechanical connection to an old-fashioned speedometer cable, nothing electrical. Shows something with three little cogs and reminds you to be sure they are correctly engaged when assembling/disassembling the front wheel. Or is the sensor you're referring to something up at the top end near the dashboard unit? If the latter, I'd definitely want to deal with it BEFORE putting the windshield and other front plastics back in place.
Also, FWIW, the electrical schematic shows the speedo as part of the dashboard cluster, but it has NO electrical connections whatsoever, unlike the other gauges and idiot lights. Seems to me it must be mechanically driven somehow; will have to identify that speedo cable down at the wheel end and trace it back up to the dashboard.
RapidJim made me aware of a cable on the LEFT side of the front wheel that indeed connects to an electronic sensor for the speedo, and to something somewhere up under the hood, so will have to investigate that before closing everything up again.
Latest, found speedo sensor down on left side of front wheel, RapidJim looking into whether Ice bear has one in stock and for how much. Part I pulled is just a small plastic gizmo at the end of a wire harness, easy one-screw removal, but everything I've googled shows these sensors with a collar that appears to be integrated into the front wheel hub. Really hoping I don't have to pull and disassemble the front wheel to solve this. Meanwhile though, scooter is all back together and rideable, just don't know how fast or far I'm going for now. Can live with that.
New speedo ($65!) arrived from Ice Bear, new one-piece design so no alternative but to remove front wheel and partly disassemble the axle hub. Hope other than that it'll fit and solve the speedo problem.
BUT, issue with mufflers now, heat has again cracked the brackets on one. Have decided to modify the exhaust pipe to support just one after-market muffler, can't be worse than those low quality OEM mufflers. Fancy looking but the "metal" must be made out of peanut butter or something. $50 to modify exhaust pipe, $40 for generic eBay muffler, $20 or so for clamps/hangers/etc. So chalk up one more quality issue against Ice Bear. Brakes, carb, enricher, two fuel pumps, electrical switch and sensor issues, what will go next? This shouldn't be happening at just 2500 miles.
Finally got all the necessary bits and pieces to remodel my exhaust system from dual down to a single aftermarket muffler on one side, and it survived a 20-mile test run okay I think. Need to recheck and tighten everything this morning just to be safe. A little louder, but nothing like Harley grade, so shouldn't earn me any tickets. Will see if different back pressure will require any mixture tweaking over time. Also have to re-fasten one of the front plastics, always hate it when I have to remove any of those, never want to go back on quite right without a struggle. There's always duct tape! But knock wood, ready to get back on the road aside from some day needing to replace that speedometer sensor. Just in time for cooler fall weather, thank goodness.
Oh, about the exhaust thing: in removing the old exhaust pipe, found it wiggled quite a bit, not really tight-tight at the engine end, and I found no sign whatever of an exhaust gasket. There's just the pipe, a steel flange, and two bolts. In replacing it, tightened the bolt as well as I could, flange is snug up against the engine, but there's still a little wiggle in the pipe, which doesn't seem right. I emailed RapidJim to ask about it but got no reply. Any Magnum-Zodiac owners out there know whether there ought to be a gasket instead of just an iron-to-iron connection?
Got gaskets on line per RapidJim, yes, part metal/part fiberglass or whatever, fit fine, more or less solved the wiggle problem.
However, out on a run yesterday, scooter quit, trailered it to Mr. Fixit, if he gets it to where it starts consistently and appears to run smoothly, next stop will be Craigslist. I've finally had it. Actually considering one of the smaller CanAms!
Ya I think it's wise,,,I personally would have jettisoned that thing quite some time ago,,,that's funny that you say that I actually have both my scooter and my dr350 for sale on CL and am seriously considering a canam,,,after dam near 50 yards of riding 2 wheels it might be time for me to not take off the Spurs just yet ,but at my age I can't afford a fall down