shadetree

sooo..is this a bet ??..lol. i know milky oil when i see it, oil is not that color that is in your pic. all atv engine oil turns black over time...that oil looks white too me ?, and this tells me its got water in it. as it was pointed out from AKATV ^^, there is water drops on the starter gear !. another sign of water mixed with the oil. i'll stake my rep on this...right along with that 100 bucks !..lol. i know what engine oil looks like when it has water in it, 30 plus yrs doing this has my back !..lol.

jumping out of gear can be anything from the shift motor not doing a full shift ?..all the way down to a bad shift drum or shift forks, bad gear dogs on one of the gears ?. and this means a total engine tear down.

100 bucks say's its been sunk,,,any takers ?..lol.

do me a favor, have a look at those allen bolt heads, and see if they are tight ?, in this pic ^^..they don't look like they are all the way down ??. while your at it, check to see if the flywheel has sheered the wooddruf key ?, if it has ?, then this is a big problem for the timing...also as to why it ain't sparking !. when ya go to install the stator cover back on ?, MAKE SURE YOU ALIGN THE NEUTRAL SWITCH WITH THE LONGER END OF THE ROLL PIN FACING/OVER THE LETTER N BEFORE YOU GO TO INSTALL COVER !. this is very important !!!. that tang sits inside the shift drum slot on the end of the shift drum.

no way in heck has this engine oil not got water in it !!..thats milky from water getting into it. i've worked on these for over 30 yrs, you can not tell me that oil is normal !..lol.

you are in great hands here !.

silver !!!.

only person i see trying to stir the pot is this person ^^^^..hmmm.

welcome bigaxejack, nice to have ya here !. fine bunch of helpful folks here. both of your machines i know very where as far as mechanic wise.

no, you do not need to pull the motor, no, you do not need a spec tool to pull the flywheel, flywheel stays on. all you are doing is removing the rear engine cover, which has the stator and pick up coil attached to it.

all things aside, its either going to be something to do with the stator/pick up coil ?, or the c.d.i. ?.

i can't make out the part numbers on that c.d.i. bag ?, what does it read ?.

this tells me your c.d.i. is the problem. old c.d.i. is bad. sounds like this '' new '' c.d.i. is a after market c.d.i. ?..when you purchased it, were you sure it was for the correct year, make, model for what you have ?. anytime you get a intermittent spark ?..this is a dead give away that the c.d.i. is bad. for the record, the c.d.i. is the ignition control module.

have you tried new c.d.i., unscrewing plug boot...check for spark off engine ?.

those numbers are low, but not high.

i just have to ask !..what good is it if its smoking when making top end noise ?, why does it matter if its charging or not when it has top end noise ?..please wizard..tell me !..lol.

here's an easy way to test stator..first..toss that manual for now..lol. unplug the stator from wire harness, with multimeter set to ohms, probe two yellow wire connectors on stator side, then move one probe to the next yellow connector on stator side ( plug )..do all 3, your looking for anything around 7 ohms, no more than 9, then leave red lead in each yellow wire connector, then probe black lead to case.engine..you should have zero numbers on meter. be sure to move red probe to all 3 wires on stator plug side while grounding black probe. if you have any numbers at all when doing this ?..then stator has a open circuit.

you need to just ohm the stator with a multimeter. and where did you get the left switch from that you said you replaced 6 months ago ?..plz don't tell me amazon !.

have you tried a new spark plug ?. have you ohm'ed out the stator ?.

try putting old c.d.i. back in. check for kill switch not centered ?, make sure neutral light is lit on dash ?.

just guessing, lack of round up ?..lol.

with it being 24 yrs old ?, its hard to narrow your issue down. the piston, or bore can be worn ?, the connecting rod can have play in it ?. wrist pin top at rod can be worn out ?, valves can be out of adjustment ?. really hard to tell you what it can be. the only way you will find out, is too tear the top end down, and inspect the piston, bore, valves, rings, connecting rod. BEFORE you tear it down !!. make sure to have a top end gasket kit, and a tube of yamabond or hondabond on hand !...DO NOT USE RTV SEALANT ANYWHERE ON THIS ENGINE !!!. i'll go out on a limb here, and say your piston, jug, connecting rod is worn out..one of these..or all 3 need to be fixed.

maybe one day you will hit your state lottery too huh ?..lol.

i hope it does...keep us posted on what happens !.

lol..that is a 2003 trx450FE !!. 10th digit, my cheat sheet says its a 2003 trx450FE. this explains the c.d.i. , reg/rec not working !.