Frank Angerano

Welcome to Quadcrazy! Congrats on the bike. 1. You definitely need a battery. Although the bike can self support its own spark and run, the battery by design is to support the additional features (lights, accessories) and assist the voltage upkeep. 2. The knock coming from the engine can be from a lot of things. Some are not a worry others are. This is going to sound stupid but I narrow it down using an old fashioned trick. I take a broom stick and cut it in half. I put my ear to one end and the other on different parts of the engine. You will hear it through the stick louder as you get closer. Silly as it sounds it’s a big help narrowing things down. It could be a valve adjustment, easy look it up on YouTube and you will see how easy to do. Second could be a clutch knocking as its spinning as it’s spinning at idle they tend to make a knock, also adjustable. The cam chain could be a little loose and my need a new chain tensioner or a stretched chain but that would throw the timing off a little and you would hear some backfiring possibly. Or worse and could actually be a main bearing. Process of elimination. 3. As far as the shifting goes that’s just the way it is on 4x4’s. All four wheels spinning at the same time. Just make sure it’s not in a low gear setting if there is one. I don’t think it would go more then 50mph at best. 4. I would make sure your carburetor is good and clean as it could be causing a little hesitation in the throttle. Great idea changing the plug and some fresh gas but you have to make sure the fuel is flowing properly from the gas tank and the carb is clear and adjusted right. 5. The clicking sound is most likely coming from a worn CV joint on an axle. You can buy a new or rebuilt one on eBay. Take a deep breath, make a list and tackle each item one at a time. Also check the fluids on the differentials. First things first get a battery. Amazon $50 bucks.

It’s always good to post pics for the forum. A picture is worth a thousand words. Plus you should be proud of your work! The next guy with the same machine with the same problem will have something to look at down the road.

Nice work @JacobSlabach any pics to share?

You are welcome. Ride safe.

It has a manual shift transmission but not a manual clutch. When you put the bike in gear the bike will sit and not move. When you hit the throttle the bike starts to move ? That’s the centrifugal clutch expanding and grabbing. So you can’t push start it.

Simple test is as the starter is running/stuck I would unplug the wires going into the starter solenoid and see if the starter stops. It’s the small plug going into the solenoid, If it does stop the starter from spinning then maybe the starter button itself is getting stuck. If your handy with a tester you can do a continuity test.

I would take the pull starter cover off and try to spin the engine just to see if it’s all good. Might as well repair the pull cord while you’re there. I don’t think towing it would be a good to see if the engine spins. Stick with bench testing and replacing the starter maybe and go from there. But having the pull cord work is a really good back up in case the battery dies. So if the bikes worth it then spend the money.

My guess is the starter relay is getting stuck. I would start there because it’s a cheap enough route to go at first.

If the starter spins freely with power applied to it then it may be good. But be aware that sometimes it will spin without the load of the engine on it. So just because it spins in a bench test does not mean for sure it’s good. Also try to turn the motor if there is a pull start. If not take the spark plug out and one of the side covers off and try to spin the motor by turning the flywheel or clutch.

Your getting the sparks most likely due to only a couple of things. 1. Bad starter or brushes inside the starter. 2. The engine is locked up. 3. The starter gear is jammed up or broken. I would pull the starter and bench test it with a battery.

Yep!!!

I cleaned it up a little bit for you as well as did some studying. It’s a little different from my model but still pretty straight foreword. Hope this helps. If you have any questions let me know. If it’s not clear then private message me and I will email it to you.

I love his avatar! Welcome back.

@Jcolgin can you post a few pics of the spark arrester ? I want to see how it broke off. This way we can give you some help/suggestions.

Welcome to Quadcrazy @Edcl54 !!!!

Your all very welcome. Big thanks to Quadcrazy by putting us all in one big room (the forum) so we can show our toys off and meet great people and help out and get help when needed. #Quadcrazy #Topnotchforum #happyeaster

Are you positive of the year and size of the bike ? I’m looking at a few diagrams and I’m not seeing this wire configuration for some reason.

You guys keep up the hard work lol the videos are great. As much as I love riding the trails and through the woods and go as hard as I can I feel like @Yamaha Grizzly @mikeexplorer @Gunny Really push the limits with exceptional videos. Aka off road dan with the YouTube specials !! It all makes for for great fun and enjoying the outdoors. Sometimes expensive but enjoyable. Keep it up. 👊🏻

Either or. My guess is the rings and if so then might as well throw a new piston in. But do your research before you start tearing into it and ordering parts. Test and process of elimination. Head gaskets etc. a compression test will tell you a lot. Also keep in mind that you can shut the gas off, take the wire off of the spark plug. Spray the top half of the engine down with a soapy soliton and crank the engine. You would see bubbles if something is pushing air out of the engine like a head gasket.

Can you post a few pics of the existing stator coil and pick up coils including the plugs and color of the wires.

The intermittent spark thing really sounds like a bad connection. I would open the stator cover and check that there is no rust or corrosion on or around the stator/magneto. Check all plugs and before you plug them back in add dielectric grease to the plugs. If the bike is cranking when you hit the starter then the starter safety relay circuit is working. Easy way to test it to put the bike in gear and try to crank it. It should not crank. The stator coil should should read from wire to wire about the same ohms. And should NOT read anything from each wire to ground. I have to go back and look at the pick up coil and stator coil numbers to see where your at as far as readings. This should be your working diagram. Let me know if you need any clarification on the map.

The black plug could be two things. One is a need to adjust the carb maybe two rich. Second is its fouled up from oil blow by if the rings are on the way out. Possibly from over reving. I would try a couple of things. First and foremost I would take a compression reading and see what you have. Should be well over 90 possibly to 110. If not then there is a problem like rings or a seal. Secondly is a slight carb adjustment on the air fuel screw. The last thing I would also do is ride the bike and wait until it gets that hard to start condition and have a new spark plug ready to go. Pop it in (don’t get burnt changing it ) and see if the bike fires right up. If so then it’s most likely an oil foiled condition. As far as the smoking on the head when oil burns off if it’s leaking from the head it’s hard to spot because it burns right up. But the over reving is not good at all and could have blew a seal or wore the hell out of the rings.

Ok great. Post some pics when the bike is all together and running good. Ride safe.

i am not home now I will send one later on today. I’m sure you can look up images on line. I think the part number is G119 but I’m not 100 percent sure. Look it up on YouTube also there should be a video showing an image of what it looks like.

It may be something caught in between the gears jamming it but that piece jamming and it most likely is a broken gear tooth! 😢 If you can’t get it to spin then you might have to split it but be prepared with the gears and seals it’s not a simple task.