i would just hit up ebay and find something close and just modify to fit. You could pull the flanges off the old and weld to the new if needed

 

I have been on ebay but most exhaust are high performance and require a higher compression, change in jet, changes to the clutch and the CDI. This is for my 5 year old son who I am teaching/training on how to use an ATV. I have limited the throttle control and plan to change the CDI so I can use the jumper to limit the max speed to 15 mph.

 

I did a compression check and it's just over 90 PSI. Although I'm not sure if this is the problem. I checked the width of the belt and found it to be badly worn out so I purchase a new one and installed it. Meanwhile I cut the muffler open and found that the pipe was blocked and compressed air would go through it. So we did a bypass and now the muffler is free flowing and in working order.

Down fall is that after all this the bike still has no power. When I lift the rear wheels and hit the throttle they spin and man do they spin. But put it on the ground and sit on the bike and it just won't move without a little help. Could it be the variator? I did try running the atv without the muffler with the same results... just won't go but does rev up.

Any help would be appreciative.

 

1 more time....Take them clutchs apart!!!
Spinning bell:: I just hold it with my hand and impact the nut off.
90 comp is ok for now. Much less and it's time to freshen the top end.

 

Aye! Next chance I get I'll pull the clutches. I'll take the time to clean them and check the variator rollers and the drive clutch springs. Anything else I should be looking for?

Thanks!

 

Check the secondary or driven clutch as well while in there...they are often neglected...