Frank Angerano

Double check the timing. It’s possible the timing jumped a few teeth.

Have you tried to pull the spark plug out, turn the key on and test for spark by pulling the starter cord? There is or should be a compression relief lever on the right side of the top of the cylinder head. Have you checked the kill switch? If all of that checks out there is a neutral safety switch you would locate and test with a piece of wire. On the left side of the engine where the shifter is, on the top of the motor casing cover in that area you should see two wires coming out of the engine. One is red and one is a light green. Unplug the green wire and put a jumper wire from that green on the harness side to the black (negative) terminal on the battery or any good ground point on the frame. Turn your key on and see what happens.

The cdi is a sealed until. And it’s that way for a reason. It hates moisture! Any moisture gets in and it’s dead. I learned this a little while back while I was putzing around with my old cdi and went on YouTube to see what anyone has to say. One guy pointed me in the direction of putting the cdi in my oven. It worked believe it or not! Check this out.

Those should be a 10 millimeter bolt by about a half inch in length.

Welcome to Quadcrazy! Those are some nice bikes you picked up. What kind of shape are they in ? Post some pics, and any help or questions please ask away. You will love and enjoy this forum. We have a lot of knowledgeable members here.

They go back to 2009!

Welcome to Quadcrazy, sounds like a nice find. All the things you want to do are all easily within reach. Post some pics and start ordering some parts! The new stereo mounts are easy and very cool. They connect with your smart phone and connect via Bluetooth. I picked up a really nice winch on Amazon for $90 bucks led lights are a dime a dozen and work well. Any help you need ask away.

Sunshine the two wires going to the thermo sensor at the radiator, take a piece of copper wire and jump them together!!! With the key on the fan should immediately come on. If so then your good to go and it’s just a matter of the engine coolant reaching temp. I also want you change that thermostat if you can. It may have trouble opening and not allowing coolant to circulate properly. I don’t think it would be a water pump but start with the thermostat.

Do you feel the relay clicking when you turn the key on and off?

I love it! Have a blast this weekend and ride safe.

Try this. Leave the key on and pull the relay. See if the relay clicks when you pull it. If so then the relay is working. Or just touch the relay and see if it clicks when you turn the key on. What I would do next is trace the wire that feeds the lights and disconnect it. See if that changes anything. Does that bike have a digital screen on it ? Any codes ?

No oil !

That is a great idea. That’s redneck 101 right there. Quick question. That front of the ac where the filter is. That’s the intake portion, how come you leave that exposed taking in the hot air from outside ? Why not build another cowl like you did and connect it to the tent as well. This way your recovering more cooler air from inside the tent then drawing the outside hot air ? Either way I freaking love it.

Welcome to Quadcrazy Charlie.

Looks great. What year is that? The headlights and bike over all appears to be a newer bike ? Very well done! And welcome to Quadcrazy!

You can bench test it. Basically put it on your work bench and put power to the stater for a second. It should spin. Black cable on the metal part of the body of the starter and touch the red cable to the lug where the wire bolts up to the starter. If it does not spin then it’s dead. Order a new one.

Ok great so keep going trough everything to rule out any shorts including a good inspection of that 4x4 selector switch and see what you come up with. Hopefully you put the oem regulator in and the cdi and she fires right up. Leave that 4x4 selector unplugged before you try to fire it up and see what happens.

Hay @Travis Mitchel welcome to Quadcrazy! Nice bike you found there. First picture without the gas tank plastic ? Second pic with it on ? The bike looks in tact. If that bike was sitting out in the elements and the kill switch and ignition aren’t working it may be a matter of just cleaning the contacts and adding a little dialectic grease spray on them. If not then maybe you have to see if the wiring was messed with. I like the older bikes!! You can do whatever you want to them and it only makes it better. A little sanding and some spray paint and that bike will look great. How did you come across it and how does it run aside from the kill switch issue ?

So looking at your diagram that you posted. That pick up coil is bridged so automatically you will get a continuity reading on that. Along with the ignition coil etc. unfortunately you really can’t test a cdi. But you can test the other two items, pick up and ignition coil. That information should be posted in the manual as far as the acceptable ohms reading.

That’s some good work. Just keep one thing in mind and this will throw you off a little bit. There are resistors inside some of the components with the cdi and other items like that work like a light bulb. For instance a light bulb is connected to a ground and a positive to make it work correct ? So you should get a resistance reading on the red and black wire going to that bulb because the element inside the bulb bridges the red and black wire but at a very low resistance rate. That’s why a lot of the repair manuals show how much of a resistance reading you should get on certain parts. Like you pick up coil and or the stator etc. So don’t automatically think it’s a short when you get a continuity reading.

Lighting connections will not stop it from running. This harness should work for your bike, take a look at the images and compare the plugs. https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F303186573464

Ok so if I’m understanding this correctly you have a 1989 4x4 bayou 300 harness from your bike? You picked up a harness and it’s for a 4x2 bayou 300? The years that you will find fit are from 89 to 92 I believe. There are a few on eBay and the 400 bayou 4x4 will fit for the 89 300 as well. You can compare yours to the ones on eBay as the pics of the harnesses are pretty clear. What I would do is if possible take both harnesses and put them side by side. Open the tape up on both of them and see the differences. It may be possible to add what you need by copying the original harness if nothing is too burnt up.

I’m confused, the bike you have is an 89 and you bought a 2002- 04 what ?? Bike, harness ? If you can explain a little better so we can maybe help you out.

Anything is possible so yes the 2x4/4x4 could be causing a short. Can you see if there is a purple wire coming off the cdi and trace that back to maybe the brake switch your mentioning and disconnect it. Test it this way and see what goes on. The 4x4 selector if possible unplug it and see what happens. I will go back and look at the diagram and see what I can find.

Ok I’m back. So that red wire on the starter is clear yes ? No shorts and no continuity from red to ground ? Tye three wires you see are ground wires. No issues there. so I would go after that “P” wire coming off the kill switch and disconnect that and see what happens. This will isolate half of the system. It’s the one I circled in blue on the diagram.