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Discussion Starter #1
A few months ago I was riding with some friends and threw the drive chain twice. When the machine was new, I threw the chain and cracked the case under the gear selector shaft. Patched it up well enough that it barely leaked and ran it like that for years, so I never put a good case saver on it. It finally caught up with me. Recently, I threw the chain and rolled it back on and started back for an adjustment check. But I did it again on the way back. It was a violent, sudden stop for the engine as the chain piled up on top of the gear selector shaft. After that, it had a no start condition. Nothing sounded crunchy inside when cranking, so I tried a pull start; still nothing. Tore it down recently to have the case repaired and replace the selector shaft. Figured the gear position sensor wires had gotten pinched (It looked that way, but the casing was unbroken) and it would be an easy fix. Tested them for continuity today; all seemed well. Had both case covers off, nothing looked mangled. Pulled the flywheel off (With the correct, safe tool) to check out the key; all looked well. Pulled the clutch off to remove gear selector shaft; all seemed well. There was a bit of play between the transmission input and output shaft, but I think it's always been that way. Had the valve cover off; no broken cams. Honestly, everything easy to see inside the case covers looked brand new. My mechanical experience inside ATVs is limited. Is the flywheel rubber bonded like on a car engine? Could the outer piece of the rotor have shifted? Again nothing on the rotor or any other internals looks mangled. Could the sudden stop have toasted any electronics? I didn't check compression. Any ideas or missing info I need to add would be appreciated!
 

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One thing to check, I have seen the cam sprockets spin on the cams after a sudden stop like that, which would throw your timing off. Take a pic of your cam sprockets and the lobes on the opposite side at TDC. They should be pointing at 10 and 2 o’clock position.
As far as I know, the flywheel is a solid piece.
 

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Discussion Starter #3
One thing to check, I have seen the cam sprockets spin on the cams after a sudden stop like that, which would throw your timing off. Take a pic of your cam sprockets and the loves on the opposite side at TDC. They should be pointing at 10 and 2 o’clock position.
As far as I know, the flywheel is a solid piece.
Thanks! I'll be sure to check that out and grab a few pictures next time I'm into it. After stopping at the shop i bought it from, cams were my next stop.
 

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Does it have spark? The stator wires are in the same area. If one of those got broken, or are touching another, or a ground, it could stop the ignition from working.
 
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