Frank Angerano

Was the stator an oem ?

Should be on the bottom of the engine near the shifter, there is a sensor. And also a relay near the fuse block and start relay. Take a look. I attached a few pages form the manual of a warrior that should be similar. You can also find the manual to that bike on this site in the upper right tab and go to downloads.

The rectifier if shorter aka burnt up may be causing a grounding of the electrical system and could knock out the ignition circuit. I would correct that and see what happens. And also go through the entire harness. Maybe it’s hit, damaged corroded at a connector and also the kill switch assembly.

Also check your neutral safety switch.

And if you are hesitant about taking the battery of of the bike you can do the test with the battery on the bike as well. Simply take a voltage reading on the battery with the bike off and start it up and do the same. You should read about 12+ volts with the bike off. With the bike running you should read 14+ volts.

No it won’t hurt the bike. It’s to determine if your battery is getting voltage back from the engines internal charging system. Fuses on that bike should be located around the battery but shouldn’t be difficult to locate. What model and size is the bike? If you have the manual you can locate the fuses.

You need to test the charging system components, stator coil, regulator, the manual will tell you what the readings should be. A standard ohms test will tell you what’s going on. Also look for the easy stuff like damaged wires, blown fuses. Make sure that the battery itself is not bad also and that there is an accessory that’s not draining the battery. Plow ? Lights ? Also: You should have voltage on the positive and negative battery terminals when the bike is running without the battery in place and a tester clipped on to the battery leads.

Makes sense

Ohh boy. All back together and running ?

Take a look at this pic, I added a red arrow pointing to the tab but would only apply if you have the metal tab on your float as some floats are only plastic. It gets bent in any one direction two things will happen the float will push up to soon or not push up far enough resulting in a flooding of the carburetor. Good luck.

I’m wondering if you have the float set at the proper level. Is it possible that you bent the tab that holds the fill needle in the bowl and maybe prematurely cutting the fuel filling up the bowl to the proper level? Maybe take a look at that it happens.

It may not be a fuel issue. Could be a pick up coil getting hot or an electrical break down where something is getting hot. Or high rpm throwing off the timing of the spark at the pick up coil maybe but that would only happen if something was loose (flywheel) keyway.

Have you checked the fuel valve (petcock) ? Make sure fuel is flowing from the tank. If that does not work then I would think your fuel is not entering the the carb where the float needle is. I know it sound repetitive but you missed something. Go back blow everything out and double check. Main and pilot jets all clear ?

It sounds like something is back feeding power into the ignition circuit somehow. Maybe an accessory? Plow lights of some sort ? I would get a tester and see what wire gets power at the ignition plug when you turn the ignition off and trace that back. Also check the entire harness for damage. Wires get hit all the time or areas where the harness is rubbing against the frame of the bike wear away the tape and insulation. After that i would start checking the stator coil, regulator, and secondary coil with a tester for proper ohms that’s shown in the repair manual. If you are not sure how do do that we can kinda walk you through it or check on YouTube as well it’s very helpful

Welcome to Quadcrazy, is the ignition switch new? Replacement? Maybe damaged? I would take it out and inspect the switch as well as any crossed wires. See if someone removed the plug and maybe hardwired it ?

Pic of the vin #?

Nice work!

I’m glad you got it out. All back together ?

Quick question. The float in your carb is sticking the main fill needle connected to the float that’s allowing fuel to enter the bowl? Reason I’m asking I recently picked up a carb cleaning brush kit from amazon. It will have a brush in the set that runs up and down the port cleaning and brushing it. And that needle can be scrubbed with a scratch pad along the side rails where it’s probably getting hung up. It’s a tedious job but it works if that’s the only thing going on with the carb. Just a thought. I tried to upload a pic for you to see but there is something going on with the site I think so I can’t upload anything ??? $8 bucks on amazon Anyone reading this post that works on bikes I recommend having this set. Carb Carburetor Cleaner Cleaning Brushes Kit, Small Wire Brush - 20 Needles + 10 Brushes https://www.amazon.com/dp/B075J7M7B4/ref=cm_sw_r_cp_api_5JSIAbGDQ3EQY

I put that carb on my Polaris 200 Phoenix. And also my 90cc Polaris predator. It worked great! Could not believe it. I figured how could a carb for that price work. Especially on my predator because it’s a two stroke oil injected carb. So far so good. I sold the 200 and still see the bike out there riding good.

Nice job Rez! Glad to hear it’s fixed. Happy riding brother.

Hey hoghead what’s your question ? Aftermarket as in a generic or an upgrade ?

Click reply and below that you willl see an icon that says click to choose files. Select pics and they will upload. If you can’t figure it out then add the vin # in your post.

Nothing like a project bike !!! Welcome to Quadcrazy @Repair, think about how deep you are into this project. Would you really feel 100% comfortable knowing that the case is “doctored” up? Between the constant heat and cooling process which = expansion and contraction, I don’t think it will perform very well. Maybe in the beginning but not for long. I’m sure you can find a casing somewhere. My personal feeling is..... Im wrapping up my 6th project and I asked the questions to a few friends on this site in particular about what to do and where to save and where not to try and save. Even if it meant holding up my project for a few weeks to find a few bucks. The end result was so much better. And the answer I think here is brother “doctor up” something that’s not that deep! Not the heart of the engine. Good luck. Post some pics if you can we love to see progress photos.