Just got around to replacing the piston rings, head gaskets and intake valve.
I checked compression and only got 90psi. did a leak down test and had to hold the flywheel at tdc in order to test ( was using 100psi input and gauge set at 90) determined I only had 5% leak by which should be good.

I made sure I set the cam sprocket at tdc along with flywheel. valves set to spec. I still can start it holding the starter and building compression enough but I'm running out of options/ideas very quickly. pleas help this noob out so
my daughter to finally follow her brother around on his dirt bike.

 

How did the exhaust valve look? Mine was pretty bad and the seat was pitted from carbon build up. I bought both valves new for $23 and lapped them in. It took a little lapping, but the exhaust seat cleaned up. The cylinder looked good, so I left the rings alone. She fired up and runs good. I will check the compression and see what it is now. It was 90 psi.

 

The exhaust valve was fine. no pitting. I still lapped it in a little though. I don't understand what could be wrong. Is there anyway I put the cam in wrong? Is there a specific way to set it? I made sure the piston was at tdc center and the cam sprocket lined up with the marks. I wonder if I rotate the sprocket 180 degrees if that would be the tdc center.

 

Did you find the "T" on the generator housing? That is supposed to line up with a mark on the crank case, but mine didn't have a mark to line up to. When I took mine apart, I found the plated link on the chain, lined it up the cam mark, and made my own marks on the generator/crank case. It might be tough to do if yours doesn't have the marks on the crank side. good luck.

 

I found the mark on the housing and basically made my own mark on the case by using a straw in the spark plug hole and spinning the motor until it was at tdc. it's looks really close to the manual.

 

Mine the two issues where sharp (leaking) valves and weak spark. After the valves were fixed it would push start ok and start on the starter when warm most of the time but seldom when cold. A inexpensive spark gap tester confirmed my spark would only jump 1/4" gap.
I ended up replacing both coils under the flywheel as the ohm (resistance) reading was out of spec. After this I could increase the tested gap to @ 1/2" and the bike started with ease.
Ken

 

I know this is kinda off subject but does anyone know where to find the air box covers for the badgers? From my understanding they do not make the part and everyone and their brother has carelessly lost the one on their bike.

 

Think ebay is your best bet.

 

Honestly I've been everywhere and I have seen nothing. I'm hoping someone can shed some light on my situation since no one has made a thread about it.