Leaderboard

Got em. Let the fun begin.

I like to use http://www.2wheelpros.com/ to look up items. At the top of the page on the right is a button that says OEM PARTS. When you hit that it you will be taken to a page with most all manufactures listed. They have one of the best layouts to look up parts I have found. I often then use https://www.partzilla.com/ since they have a warehouse close to where I live so it's always fast shipping.

@Frank Angerano is right, see without any compression how that starter cranks. If its still slow like it is, might be a bad starter if that battery is fully charged.

Ahhhhh ok i didn't realize you changed the battery. So yes see how it cranks without the spark plug. It really can only be a few things. The starer and or brushes inside of the starter. Or the decompression weights inside the top of the cylinder head on the cam. Sometimes the small springs on the cam weights come off. But go the starter route first. You can pull the starter off and bench test it also if your handy. If you pull the spark plug out and it still had trouble cranking then it's definitely the starter.

Looks like a good project to me. You're going to be impressed by the 4wd.

Ya, I plan on draining the front diff as well. Good point on the battery causing the corrosion. I looked inside the best I could, I don't see any rust down low - I hope that, although water and oil separate, there was enough dilution in the water to prevent corrosion. The upper end took the worst of it, cylinder and piston as there was no oil to protect them and the rings allowed the water to sit there. I hope all will be good, I'm waiting on the new rings to get here to put it back together and test drive it. thanks

There should be one by the battery. There is a round small relay. Usually right next to it is a fuse. Take a few pics and post them, we will point it out if its there. On some of the smaller atvs it different. I haven't looked at the manual but it should be there. Have you located that fuse #3 on your diagram? And lastly some of those bikes had the emergency rip cord to shut it down in an emergency if you fall off the atv as well as a brake switch where you have to pull the brakes in to start.

Ok I thought you meant melted or burnt up. It's most likely something simple that was overlooked on the reassemble process. Take a look for that fuse i told you about first and then go back over your work step by step. Im thinking a wire got pulled out of a connector someplace. Double check the kill switch and ignition as well.

That's quite cool. I've added my location if I did it right. Nobody near me here in Australia, but give it time and it will expand. Well done.

Add one of these also.

Nice bit of carbology! Helps take the what to many is mystery out of the process.