Frank Angerano

True story !!!!

Welcome to Quadcrazy. You found the right spot for atv’s. Good luck on the restore! So what shape is it in, year etc. Is the bike running? I’ve done quite a few bike restore and would share any info on what I’ve done to save me money, and time not to mention that there are so many memebers here that can also help along the way. So good luck and share some pics of you can. 🤙🏻

It’s on the outside I believe . And yes the cold is a bi*** especially when you bang knuckles lol 😮

Sorry I thought you had the engine apart. There is a gap that you are more then aware of based on the responses you’ve given. You seem knowledgeable. That gap may have changed from any number of reasons. One being something in the engine that let loose. Small piece of something inside the engine maybe ? Anything’s possable. I think the swapping of he cdi if yours was bad would have fired up even with the years in difference as long as the plugs matched. How about the kill switch testing for continuity? Sorry for the repetitive questions, I’ve missed things in the past. Just want to make sure before you go ripping into the engine. Or get deeply involved if it’s something right in front of your face.

The wiring could have changed but you would really have to compare the two diagrams to be sure. The stator coil should read no more then 0.63 on any of the legs. The voltage seems low also. Also the pick up coil gap to the magnet have you checked the gap? When you checked the secondary coil did you check it with the spark plug wire on or off the coil? And have you tested the spark plug wire as well? The kill switch you tested for ohms... did you check that you have and opened and closed circuit (continuity) on the switch and that it’s not making partial connectivity and not fully opening? The switch could be bad or corroded inside. All the components inside are made of brass or copper which are all subject to corrosion/oxidation. Im going to look at the manual and see if anything stands out and try to help you out a bit. I’m sure someone on the site has had this problem and will chime in as well.

Great pics. Looks like you have a lot of room on that shop. Great work! Any surprises?

Maybe.... but it looks very shallow and now run the risk of getting shut down before they even get the opportunity to get the manual. You can reach 10 posts rather quickly but whatever. Is what it is I guess.

Ok so let’s get into the wiring harness and start going through it all. This is something we are going to help you out with. There are quite a few ppl here like myself that will help. If you don’t mind can I ask how you tested the stator ? I’m sure yiur more then capable but I’ve made mistakes on this before.

I agree w @Ajmboy it’s sad that it’s continuity going on. 1,2,3,4 on and on and on. Anyone who does this should be flagged and booted before they even get close to the 10 count.

Is there a part number on it

Start stripping it down and going through the harness. The crab is going to have to be cleaned plus that shifting issue. Keep in mind that even if it’s not worth fixing the plastics alone are prob worth 500-600 so parting it out you would make your money back. But you have to decide once you get into it. Carburetor * crab 🤣

So I had a friend that did the same thing to the same bike. And found that the harness burnt up inside the bundles of wires. Completely melted. He knew right away because he smelt it and seen a little smoke. Did you see or smell any of that ? How there was no protection is beyond me. He wound up changing the entire harness. The stator coil was also wasted. The only good thing it the harness was only $85 and the stator I don’t remeber the cost. Make sure there is not a fuse anywhere before you go through all of this and download the manual to review the harness. Some models have a fuseable link that could burn up preventing damage. But honestly I would check the tranny first and make sure it’s all good before you put any money into it. If the gears are shot then it’s big bucks and you might want to cut your loss now !

Ok well that’s good on the other coils. As crazy as it sounds it worked on my Honda fourtrax. It failed about two days later but I knew where to spending parts tg. Put a new cdi and bike was solid. It basically dries out the inside of the cdi. I put my oven on 225 let it get to temperature and then put the box in for 10 min. It was hot as hell and needed to cool for 15 mon lol. But it worked.

Has the bike been sitting ? What condition is the cdi in? Is it possible any moisture got into the cdi. Most cdi units fail bc of moisture getting inside. Believe it or not you can put it in the oven on 225 deg for 10 min , NO more. Let it cool off and put it in the bike. Crazy but it works! it’s a temporary fix but will tell you if that’s the problem. Second; have you checked and tested the stator coil, pick up and secondary coils?

I have and it didn’t work out very well. I tried a heat gun and that worked ok but it was a lot of work and if you get to close it will bubble. The heat restores the color, it’s spotty but like I said it’s a pain in the as*.

I don’t think low oil would make a grinding noise. I think low oil maybe caused a damaged gear and something is now broken causing a grinding noise like a differential ring gear or pinion gear. If you keep riding it most likely will get worse. I would stop riding and take it apart. Maybe you will limit the damage now and only have to replace a few parts instead of all of the parts.

Ha yea definitely need extra parts and tools. So it’s all good now ? If you can’t ride it like you want then what’s the use in having it ?

It is a great spot. Believe it or not 30 years ago you could go up there and see guys fishing and would have no idea but famous baseball players, actors etc would go. There were NY Mets players fishing there. My uncle used to take me and show me and tell me who was who.

Awesome. I had a buddy that use to ask me for all my deer tails fur for fly making. Rosco has some of the best fly fishing! very cool 👍

Most of them trailers come with the lock washers and nuts which really hold up well. But honestly I like the idea. Heck you have to put it together anyway might as well add a few drops on the bolts along the way! And it’s not like you can’t get it off. Great idea I think. When it’s together let see it !

Oh ok, dam that hurts man. Well good luck with the rebuild and make sure the head or cylinder is not warped from heat when you break it down and post some pics! I love to see pics. You found the right forum to help you out if you need! Good luck brother.

Wow that sucks but hopefully it’s just gaskets and that’s it! Do you know why it over heated ? Reason I’m asking is you don’t want to do all that work and have it over heat again. 😬

I don’t think it matters. I’ve used a few different manufacturers for gaskets. What went wrong on the top end ?

🙏🏻True ! I would like to get out there and see it. Me and my oldest have to get on the road this year! I just picked up a trailer plus I have the pick up. We have been talking about an out of state hunt this year coming and I think it’s a must of a road trip. So when does your hunting season begin and end ? Is it cold during your season. I would love to know some of those things and maybe a little more. I’ve had invites to go to Texas but I’m not a fan of hunting in warm weather. Lol. So we are going to make a move at some point and hunt someplace far from home and enjoy the views and ride.

No worries on the revolution. You set the valves when the engine is set at top dead center. Don’t worry about a compression stroke. Just get it to TDC make sure the T is in the flywheel spot it belongs and the cam sprocket is aligned with the marks on the head and make your adjustment on both valves. That’s it.