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Item 37 in this parts breakdown.

Something is froze up, that should spin....by the way, that's the mooring or service lock...there should be a double lock as well.

You said one side was hot...old school method, warmed up and fast idling...touch the top of the head where it meets the block, it should not be scalding. Port a few degrees cooler but not noticable to the human hand. Port side head have a two wire sensor? Tan wire and a white wire? Could be...

And no explanation/confirmation from the op

I'm confused, tach shows 10k....but you run at 7200 RPM's at wot? I hope I'm wrong...please explain. Also, if your rectifier is cooked, you won't see 16 volts. You will see whatever the battery voltage is.

Re-read everything. Do a spark GAP test as well. Nice, good 3/8 gap...testers are inexpensive.

Yeah, I run 750 RPM's in gear, on the water underload....in the backyard on muffs I'm at 1100. Not sure how the others can be so low but that's been my experience. If your compression is fine than I'm guessing you still didn't get your carbs clean enough. When the carbs were off the motor, did...

Compression check is in order....and so are temp readings. IR guns are inexpensive. Things could be shutting down when they get warm so take a timing light with you next time and see if your still sparking.

A 2002 shows your rectifier so that should be fine to order parts. Best guess.

1100

I also use the long screw driver.

On muffs or barrel idle is set to low.

Just checked the book and I stand corrected. 140 to 150lbs. Hope you have a good strap wrench and a buddy.

Make sure your tapers are perfectly clean and then after slightly lubricating the threads you want to use 105 ft lbs.

Right, that verifies the horn works nothing else. I think he's finding it hard to believe you have two failed ones as do I. Buy a inexpensive IR gun and take it on the lake with a partner. While they drive, take readings from where the head meets the block. Something seems a miss.

Pretty sure that motor has water deflectors inside the water porting around the cylinder walls. Did you inspect those?

Post 99 Wow. It's been so long I basically forgot what your symptoms are? How about a new video. If you make it into a YouTube (easy) it transfers better quality.

I had go carts first, mini bikes...then a yz 80 then eventually had a YZ 400 before retiring to outboards and fishing. Doing a "Raggedy Ann in the whoop-de-doos solved that!

I believe certain models had a 1 7/16 nut on them. Have you tried that?

And help profit margins for service shops...which btw seems to be a newer industrie standard.