Colasonojon9

I tried this on my 99 big bear 350 2wd and no spark but my wire colors are different I have white wire green stripe, white wire pink stripe maybe red, brown wire white stripe and green wire to CDI for pickup coil and Source coil

@DirtDemon I am having a similar issue with my 99 Big Bear 350 2wd my stator has three bolts on the inside of the case Phillips head three screws on the outside star bit also has the bearing on the inside of the cover in the middle of the stator I just need to be able to remove the stator so I can replace the source coil still waiting on my service manual to show up I have attached a picture of my stator

@Rebel50 Rejet the carb i bought a carb new/refirbished from zoom and it came with too small a pilot jet it had like a 25 in it i had a 30 just laying around got better but still not right i ordered the stick size a 42.5 from pjmotorsports huge difference runs like a scalded dog but I have other issues now like stop sparking once hot replaced all coils beside the primary coil only because I can't figure out how to get my stator off and now it only Sparks Once when you first hit the starter anyway hope that helped

Rejet the carb i bought a carb new/refirbished from zoom and it came with too small a pilot jet it had like a 25 in it i had a 30 just laying around got better but still not right i ordered the stick size a 42.5 from pjmotorsports huge difference runs like a scalded dog but I have other issues now like stop sparking once hot replaced all coils beside the primary coil only because I can't figure out how to get my stator off and now it only Sparks Once when you first hit the starter anyway hope that helped

Atached is said crack in starter clutch

@davefrombc update: installed new starter clutch sound is gone. The starter clutch had a crack in it. I imagine thats why it was clacking during turnover. Just wanted to update in case this was helpful. Also changed pick-up coil and ignition coil. I have the primary/source coil but cant figure out how to remove the stator need to be able to flip stator over and tap the source out cant find any info anywhere. Do i need a special tool dont want to break stator windings. After assembly without changing source the bb only sparks once when you start to turn over wil spark once everytime if you wait a few sec inbetween engaging starter. Please help

Well i never 100% figured out the grinding after removing stator cover and replacing starter but i do know what the loud clack is its one way bearing i turn magneto by hand and seems to work correctly then i enguage starter and hear sound clack the magneto/flywheel lock both ways deffinately the bearing.

Just to touch base ended up ordering the stock pilot jet for the brand new carburetor size 42.5 at least 2 sizes bigger than what was in carb brand new i can actually drive now still trying to tune carb in after about 20 mins of riding it wants to shut off and not start but this could either be float level or electrical heat problem ill keep you guys posted

Ok so installed my starter works fine also after reassembling the grinding is gone but there is still a clack that has been there only hear when turning over and when engine stops i think i read where this is the one way bearing i have a short video of the sound its louder in person https://youtu.be/ePrM0Gm8TaM

New starter came in but havnt been able to get running yet. Also i thought new starter motor would stop and it still has same sound i have a video to help

Okay i think this may have been partly human error on my part. I took the casing off the left side and one of the starter idler gears just fell out. I could be wrong but when i took the innerds of the starter out because the magnets inside the starter were swolen and causing the starter to clack and make alot of noise. I put the rest of the starter back in so it wouldnt leak oil. Without that piece inside starter would it be possible for one of the idler gears to fall out making said grinding noise i attatched photos and i dont see anything else that could be making that noise. I will be ordering a new starter tomorrow along with a new gasket for the cover, please let me know if im correct and headed in the right direction thanks

Okay havnt been able to solve previouse post about carb because before i could my starter locked up, ended up having to remove guts of starter to be able to use pull start, too much resistance with guts still in starter. Finally got it to start after this and installing air box and it started good about the third time i pull started now there is a nasty grinding sound on driver side seems like behind clutch adjustment going to tear down tomorrow and take a look any ideas?

okay that's good to hear I was rather gun-shy about messing with it anyway I like to know exactly what I'm doing before I go messing with something and the chain is very tight so I doubt it could have slipped anyway never know though. Of course my starter had to go out and I'm having a little difficulty pull starting so kind of at a standstill thanks much appreciated

Okay I just wanted to get a good idea where everything was this morning so I started with the timing checked it, it looks like it's about 1/16 or 1/8 off is it as simple as removing the center bolt in the Top Gear and then turning the gear without turning the chain that far and bolting it back up