Gwbarm

That is a problem, I would try to get a pry bar and pull the nut towards you, at the same time unscrewing the nut with the ratchet hopefully it will catch and come on off. If you can't get a pry bar in there , maybe you can improvise something to get a little outward pressure on the nut while trying to take it off.

I would try adjusting the clutch and see if that helps.

This is the CDI wiring on the 2000 model

Just reviewing the photos the CDI has 6 wires in one plug and 4 in the other.

Those are the same coil specs for the 2000 and it is a 6 wire CDI.

Things are going to smoothly, for one of my projects, so I have to stir the pot a little. I decided to go back and look at the cracked side cover again, I hadn't really looked it over closely since I got it off. It pretty bad, I can probably JB well it and make it work, but im not sure I want to do that. It is really clean Looking on the inside the crack circles the bearing area I can see that getting worse. Looking from the outside the crack is all the way through I can see light through it Plus the sealing surface was damaged a bit doesnt show up in the photo as bad as it really is. So back to eBay, I tried Facebook first, I can't really find the parts I need there, may different in NZ, any way I found one looked good and straight, with all the bearings and stator, the only difference I saw was the stator plugs were black on his and white on mine, so who has the aftermarket stator, who knows. He wanted 69.00 and free shipping, so not bad, it's fairly heavy probably 20.00 + to ship. Most all other ones I looked at were stripped, case only, and going for 40.00. You just can't get 5 or 10 dollar used parts anymore. Still haven't figured which rotor to get , heard some complaints about magnets not being strong enough in aftermarket units. I can see that , the originals are strong, the aftermarket ones are under another piece of metal to keep them from coming off, so it makes sense they would be weaker. I may go with RMstator from Canada I have heard they are good.

Ebay is so much fun, im trying to figure out which flywheel to buy, I go to this one seller and he has ratings, I look at his rating and one rating is for the rmstator, another is for a different brand than he is selling and so on, so I figured this is not even truth fuii. So I go to another seller with ratings he has exactly to same ratings and comments that the other seller had, word for word, so one or the other just cut and pasted the rating that were bogus to start with to his page, that's why I only use eBay when nothing else works out.

I have bough Niche parts and have been very impressed with their quality, but mostly electrical parts, have not used any engine parts.

Every thing is looking good so far , just continuing cleaning things up a bit, got most of my parts ordered, I haven't ordered the rotor yet, still trying to decide, I do not want OEM if its still the one with external magnets, which it shows in the parts diagram, all of the aftermarket ones show internal magnets. Still looking around on Ebay for a descent case, found a couple but i haven't ordered one yet, not sure if I want to pay shipping for all the mud and rust corrosion and grease on them, plus they were expensive, but what did pop up while I was doing my search was an OEM carb, which I have been looking for at the right price. I needed one for this project and then I will have all OEM carbs back on all my bikes. It was listed for 15.00 I thought, but didn't look close enough , it was starting bid, I don't usually bid on stuff, to aggravating, but the seller had a small inventory and this was the only ATV part listed, I like buying from people like that, just trying to make a little extra by cleaning out the garage,so I put 40.00 on it, close to what I paid for the last one, not expecting to get it, most go for about 80.00+. Just forgot about it and ended up getting it for for 20.00. Curious to see how bad it is, I suspect it was just taken off and replaced and stuck back in the garage. Not much to look at but it is OEM. The only thing is she said it came off an Automatic mine is manual, I don't think that will make a difference, but it might be jetted slightly different, I will have to see. After I won the bid she messaged me and apologized how dirty it was and promised to clean it up before shipping. Nice gesture!

Not necessarily a mistake, crap just happens.

Just looking at your wiring it looks very similar to the 400 I have been working on, but you do have a few different color wires than I didn't have. The W/G and W/R did go to the pickup coil and you should have had some resistance there, your stator plug looked the same as the 400, pick up coil is attached to the rest of the stator.

It looks to be all there and in good shape, not abused like the ones that seem to follow me home, hopefully its an easy fix, appears to just need maintenance.

I wasn't sure it's the only one I have been able to find for the 350 I thought it would be easier to find than the 400.

It should look like this one.

Bayou is a nice bike small light and fun to ride.

Agreed, I have known so many people that were very sick from tick bites, took a year to get over it and still having trouble.

Welcome and good luck with your projects, always willing to help.

I don't recommend them either .

This is the only manual I could find not very impressed with the wiring diagram but it might help. You might have already seen this one. Key, Wire colors are different from what I quoted you on the 400 Sorry for the bad photos I couldn't get it to copy and paste from the manual.

Well finally got it off, im not real proud of it , I ground the end a little too much, I knew I went to far, I wasn't going to take it any farther, it still wouldn't come off, I was beginning to think I had a bad cog in an area I couldn't see, so I took a pry bar behind the dogs and with very little effort it came off. There must have been one little metal tag keeping it from coming off, now just waiting on parts. Im still trying to figure out what happened with the washer, even with the gear on backward it shouldn't have eat into the shaft if it was working correctly. Got the new gear in it was nicer than I thought from the photo on Ebay I thought it had some surface rust on the bushing, hoping it would clean up well when I got it, but no rust at all, what I thought was rust was brass on the bushing, which was completely gone on my old one, must have been some sort of plating. Trying to find some new washers that I can get quickly, found some just won't be here until the middle of July, I guess I can wait, still got a little polishing to do on the shaft.

You have power to the starter so your cutoff relay is working. You can check your start stop switch to see if its working like it's supposed too. There should be a black to ground and a black and white that goes to the cdi. What I always do when I have no spark , is check to make sure you have 12 v going to CDI should be R/W wire make sure you have a good ground at CDI make sure you have 12v going to coil from CDI orange wire. Check to make sure you have correct resistance at the pickup coil, not sure on the 350 but on the 400 W/G wire and W/R wire, you can also check to make sure the pickup coil is actually putting out voltage as you are cranking. There is no test to make sure the CDI is good, the manual tells you to check all these systems and if they are all in spec and still no spark replace the CDI. I don't have a manual for the 350. I will see if I can find one and take a look to see how different wiring is from the 400 which I am quoting from memory.

I think I would replace the plug and fuel filter and see if you have adequate fuel flow to the carb. It still sounds like fuel delivery Sorry Mech I just saw you recent post didn’t mean to repeat what you said

I get them at Harbour freight.

Still working it, I got the bulk of the stressed metal off with a diamond bur and finishing up with the oil stone, looking a lot better but still can't get the shift dogs off the shaft. There are raised areas at the outer edge of the trough which I think are stopping it from coming off. I found a stone that would just fit in the trough, just slow going, just going a little at a time, I will eventually get it. It will now go all the way to the end of the grooved area and im sure will work fine, but I want to keep at it until I can get the dogs off the shaft. waiting on parts anyway, I am getting some new OEM thrush washers and outer gear, so I will be positive they will be the right fit. If you noticed in the last phot, bottom right is the stone im using, it is actually a dental instrument sharpening stone small and good to get in the tight areas.

The vin# on my suzuki is on the rear frame downtube left hand side