Mocnyang

When I replaced my stator and pickup last year on my big bear 400 the pickup coil started making contact with the flywheel. instead of draining all of the oil I put in it after the initial install I leaned it over on a stack of pallets I had. I did brace the upper wheels with blocks so I wouldn't fall on me. I Wouldn't put it fully on its side because oil can seep past the piston rings if it sits to long that can lead to hydro-lock. I did however pull the spark plug and crank it when it was back on all 4 tires to ensure that there was no oil trapped in the compression chamber.

You should use crushed walnut shell media. That's what we use at work and it doesn't do that. We do helicopter parts with it and you can't alter the part or it's not serviceable anymore.

That will work, rustoleum makes a high heat primer and vht has a nice high heat gloss black that I would recommend. Most other high heat if matte black but the gloss looks really good. Before showing it I would run it a few times, it will smell and a potential buyer might wonder.

Everybody starts somewhere, first I would drain the gas from the tank and tip it on its side like said a few posts ago. Just find something to sort of lay it on when you do so it doesn't fully lay on its side but keeps the oil in (unless you want to change the oil, in that case just drain and don't tip it). In the next steps it's imperative that you take a lot of pictures to help out when you reassemble. Also take cardboard and draw the covers on it and poke holes where the screw are for a templet for the starter cover and left side cover. The bolts will be different lengths. 1. You have to pull your starter gear cover (the black one) forst and remove the starter gears that turn the flywheel. (Pictures!) 2. Remove the bolts that hold the left cover and as you pull it off it is magnetized so it will be tough. Along with that it's probably stuck on by the gasket and will require prying it off. Most atv covers have tabs that you can pry against to pull it off if not pry against the starter mount. Try not to stick a screwdriver in there and pry on the gasket surface. As you pull it off be mindful that the shift shaft will come out when you pull the cover. 3. The pickup coil is in the cover. Two screws hold it in but first inspect the metal tab that faces the flywheel. If it's nicked or scared by any means you can loosen the screw push it back and tighten or replace if really worn. Only move it a little. 4. While the cover is open inspect everything else in there. 5. Reassemble! You will probably need a new gasket and it might be worth looking at a new stator and pickup since you are opening it up. But that's up to you. Check the oil level before starting. I hope this helps you out some!

It's definitely on the left side. What I would do is pull that left cover off and check the pickup coil. Sounds like my big bear last week after swapping one out. Can't use a feeler gauge on mine because the pickup and stator are mounted to the cover not case so i pit it on, ran it, had a very similar ticking, pulled it back off. Then loosened pickup screws pushed it back then reinstalled. She ran perfect all day mudding Saturday.

Is the plug black or white or brown? Black = rich White = lean Brown = right

Valves are probably good then, they would make a rattle sound if they were out of spec, I had a rod back off on my harley rattled like crazy. Really the only thing on the left the would make noise is that pickup contact and the starter no disengaging. If it's on the right could be something bent internally or clutch stuck open but I haven't really seen that myself. If you decide to pull off the side cover a trick is to tip it on its side so you don't have to drain the oil. I usually lean it on something so it the gas doesn't pour out and the oil can't get in the combustion chamber. Make sure you pull the plug in case any oil does get in. When im done I usually crank it with the plug out to makes sure. That works with left and right cases too!

Did you check the spark plug? Start there before tearing into the carb. If it's black and all soot try burning it off with a lighter, put it back in a crank if it starts fine your mixture is too rich and your fowling the plug.

Did you pull tyhe stator cover off? Flywheel and pickup coil contact makes a loud ticking that corresponds with rpm

So I bought one through a dealer in California, they had the best price. Genuine yamaha part not a aftermarket. Plugged it up and a it fired right up. When it started I heard the flywheel hitting the pickup coil so I had to take it apart again but I just tipped it on its side. Not all the way, I leaned it against something so I didn't have to drain the oil. Sure enough there was a nick on the pickup coil but it still worked fine so I loosened it, pushed it back fully which was only 1/16th or so. Put it all back together and it was good to go. Thanks for the help all!!!!

Yea I found those after I posted this. The funny thing though is the one that I have is actually as 2000 on a 01...odd. I'm going to my local parts shop tomorrow to see if the have anything. Even if it's a little more money I'll buy it instead of going through those types of sites. The review a just horrible. Thanks for the quick reply.

Hi... new to forum first post, have a 2005 raptor 350 and 84 atc200es and just picked up a 2001 yamaha big bear 400 2wd. It was only $500 so i bought it knowing there was no spark. Well to start i tested everything by the book fuses, kill switch, main switch, neutral switch, parking brake switch, ignition coil, pickup coil, dirction coil, stator and all of the connections in between soooo......i need a cdi problem is I can't find a cdi anywhere, searched by part number model also searched possible interchangables, no dice. It's part number is 5fu-00 F8T36471 9910. Any help on if i can use another model or where i can possible find a replacement. Not sure if this helps but it has a 8 pin and 6 pin connector. Thanks in advance for any answers I'm stumped.