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Similar Forum Topics
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By TomJulio
My 1992 TRX00 recently stopped firing. I understand this is a common problem. I have ordered an aftermarket CDI unit. TJ
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By LCP92
Guys, I've got a 1999 Honda Foreman 450S. It runs great, but smokes out the exhaust after startup until it warms up. I'm thinking the valve seals are leaking. I was wondering if there is a way to replace them without removing the head or if there's an oil additive that will recondition the rubber seals. Any advice?
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By Guest
Hey all, new to the forum! I just bought a 1998 Kawasaki bayou 300, 4x4 not running. Initially I found no spark. Ended up playing with the plug wire (made sure plug top and wiring was touching) and got spark yesterday and the quad fired up off ether. Come to work on it today and now no spark again. Before I got spark and now today if I touch the plug after cranking I get shocked, and it will spark after I release the starter button. I was jumping the quad with a freshly charged car battery that has 12v while cranking. Cleaned out the kill switch and ignition button. All looks good. Purchased new plugs. They're are a lot of wires cut/ disconnected. But shouldn't matter if I got spark without them connected...
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By DexKing
I recently got my hands on a free 2004 Recon that the owner had zero information on the machine or the history. Long story short, a little troubleshooting and research revealed i needed to replace the timing chain for it to stay running. when i opened the case, it the chain was so horribly stretched, that the tensioner pivot arm had play between it and the chain! I also found the oil pump chain totally disconnected from the sprocket due to being completely worn out. I tore the whole engine down and rebuilt it from the bottom up finding little things here and there that needed to be replaced. Upon inspecting the top end, i didn't find any bad/excessive play in the crank, rod bearings or wrist pin. Now the machine runs great, but even after 2x adjusting the valves, the chatter is way more than you'd expect from a honda normally. My neighbor is an auto mechanic by trade, and i asked him to take a listen. the look on his face when i started it and it was chattering like that was priceless! He mentioned that maybe the valves themselves might be wore out or stretched. my question here: what all can cause the excessive rattle up in the valve cover aside from valves being out of spec? Everything else seemed to be in decent condition as far as rockers and guides go. I am fairly new to small engine/ATV repairs, but am learning as a hobby and have a fair amount of knowledge with how to do some wrenching. Thanks!
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By RGS
1989 Moto 4 YFM350ERW intermittent spark.
Quad has set for about 7 years and was running when parked. When I replaced the battery and attempted to start it had no spark.
What I have done. Followed troubleshooting in the manual.
1. Coil failed the resistance check so I replaced it. Still no spark.
2. I performed resistance checks on the stator and they all pass.
3. Found a bad rear brake stop switch and unplugged it and connected the wires in order to disable. Now I have intermittent spark. I believe that the issue is with either the stator or CDI and not sure which.
1989 seems to be a transition year for electrical. I can get new aftermarket CDI units for 87-88 and 90-94. I cannot get ones for a 89. I can get new stators for 87-89 and 90-95. Looking at the schematics the wiring on my moto is closer to the 90 ones on the ATV side of the CDI and closer to the 87-88 on the stator side of the CDI. Looking at part supply sources the stator housing is the same part # for all the years and looking at some of the stators on Amazon that have the dimensions on them both of the stators are the same size.
What I am thinking of doing is to replace the stator and CDI with a 90-95 one as these parts are all readily available. Does anyone know if this has been tried before and if there are any issues with doing this.
As a side note I also have a 1993 Moto 4 YFM350ER that has been sitting longer but it is located about 400 miles from me at this time. By doing this change in addition to being able to get parts I will also have 2 ATV’s that are the same electrically.
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