Frank Angerano

Where are you looking? Lower front left frame rail ? 99% of Yamahas are stamped into the frame in the location i mentioned. Take a look its there.

Agreed on the electric stuff versus the engine stuff. The engine really only needs a few good flushes and it should be fine. No need to tear it down really. The electrical is where the problems happen, current wreaks havoc on the system in water when the shorts happen and destroys the controls very quickly. Especially the ignition parts. My guess is thats where you will spend the money. The harness should be fine though overall and just the components that are on the system.

Does the shifter feel wrong ? Is it shifting into reverse but not moving ? Have you checked the fluids in the gear case ? lastly try getting all four wheels off the ground and see if the bike goes into reverse.

Not sure what the differences are but I'm shocked it fit! On top of that if the magnifying is the same then it should work. Have you tried to put it back on and test it again?

Figured there would be a bent valve. Makes sense on the stretched chain as well. Nice work on the tear down. The dark spots in the cylinder head are they scratches or gouges ? If not then its not in bad shape. I quick cylinder honer on a drill would work fine with a fresh piston and rings. If the dark spots are in deed deep scratches or gouges then yes its going to need a machine shop. But keep in mind going a bit bigger usually will need a bigger jet kit on the carb.

Welcome to Quadcrazy!

Wow thats great news. The flywheel must have either very weak magnetism or none at all. Thats a rare occurrence to see that. Have you tried to take a screwdriver and see how strong the magnets are on the inside while the flywheel is off?

Sounds great but yes def a whinny noise. Im thinking clutch, check all fluids and take it for a good run. Nice work, you can pick up a new seat cover for 30 bucks or make your own for maybe 10 bucks.

The screw under that black hose is the air/fuel screw. Idle screw is on the side of the carburetor, either on the side or right where the throttle cable enters the carburetor That's your air fuel mixture screw. Picture attached. That screw should be 2-5/8 if thats what the manual calls for. idle should be on the side.

Both of those covers look great! Especially for the price. I would never think of road salt being an issue. Crazy the things we learn everyday.

Excellent advice by @Ajmboy ! I would pull all the plugs apart, fuses out and spray all electric plugs and the fuse box with dialectral grease. Label everything so you don't get confused as well as a few pics incase.

Getting them back in is a bit of a bi*** but they go. Sometimes you have to loosen the air box bolts a bit. The idle screw should not be hard to access. Post a pic of the screw your referring to.

In don't know or think the caltric will work but I'm hoping it does. Either way keep us posted.

Agreed with regard to the stator. My guess at this point is a bad cdi. You cant really test them. Once a diode goes bad its over. Unless there is moisture inside you cant do anything about it.

I don't know if the manual is wrong but i would think that the coil is ok. As far as the plugs etc and cdi where are you with that and everything else wire related. Kill switch wiring?

Are your tester settings correct? Both coils testing that low is not a coincidence. It's probably ok. Whats the spec on them ?

If your getting 213 ohms on the trigger coil then its good. If your not getting any short to ground on the three phases Thats good but it sounds below spec @0.6? Ive never been successful in testing a cdi other then trying it on another atv of the same kind. Ive also tried other non oem stators that claim are direct replacements but did not work. Do you have the spec on the exciter coil? Caltric makes a decent stator and ignition parts, i have them on my bear tracker and have been working for over two years. The cdi was bad also but i took my chances on a used one on ebay and it worked great. I would sort out all your parts and get rid of anything or at least put it aside for now what is not oem or questionably not good. Do the proper testing as you have been and verify that the parts are within spec, label and keep the good stuff. If your getting frustrated then walk away for a bit, this is a thing i always tell people. Its a frustrating process but rewarding when you get that spark going. Age is all mind over matter! If you don't mind it don't matter ! Lol You got this!

Hey @Mike Johnson have you made any progress with the quad?

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F303393055758

If you do the testing on the stator and the pick up coils and they fall within spec then they are good. The only voltages you should look for are from the stator. For the trigger coil/pick up coil, you can put your tester on the two wires and spin the flywheel by hand and as the magnet passes the coil you should get a reading. Take a look on eBay and I'm pretty sure you can find new plugs for the harness.

Your charging wires from the stator should be 14-15 volts at 2000 rpm. The stator resistance between phases of the stator (non rotating) should be 0.45 to 0.55 ohms then test each of the stator wires one at a time to ground with the tester in between looking for continuity. If you have continuity on any of the three phases to ground then its an instant fail. Pick up coil resistance 189 to 231 ohms What color wires are on the pick up coil W/G&WR?

See how this matches up to what you have as far as color and quantity. its from an 2001 my atv.

Ha, thats one of the best things about this forum! Who wants to wait for answers? Its almost as bad as waiting for parts.

I just realized you posted this with your make and model. I have a bear tracker so any help you need i will do my best. I will take a look and get back to you on the spec for the stator and pick up coils. Mine is a 2000 so some big differences in the wiring. let me see what i can find.

Hey @Randel1 welcome to Quadcrazy. Sounds like you have a interesting job! Well all I can say brother is you've come to the right forum! I came here a few years back looking for help on a tricky problem on one of my quads. Now prob 15 quads later i buy, fix sell and ride my as* off with my oldest son. So welcome aboard and let us know what bike you have, make year and model and I'm positive you will get all the info you need to fix it.