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Nice research, didn't realize it was a dual coil setup. I'm going to be stripping down my 83 YZ490 to the frame and doing a complete makeover. Part of which includes lights, but since I haven't gotten that far (a few big honeydo's in the way) I wouldn't have been able to give you any more info...

I haven't yet confirmed this, but you should be able to replace the lighting coil with one off an lt500r. They are 12v 85w stock and I believe 52mm eye to eye (that's the measurement I haven't confirmed on a 490 motor). Ricky Stator makes one for the LT500R that is 130w and something like $40...

can the stock muffler be repacked? if so, just put some fresh packing in it

Are you talking about http://www.electrexworld.co.uk/ ? I've bought from them and have had no issues at all. With vintage dirt bikes they tend to carry stuff that can't be found anywhere else.

She should be able to get a reprint of the title from DMV. I know here in Arizona if she gave you a notarized bill of sale that would be as good as a title. Personally, I wont touch a bike without a clear title.

When you mod an engine, it usually becomes lean and needs to be richened up. An overly hot exhaust is a sign of it being lean and so is the backfiring. You'll want to make your jetting changes one at a time to dial it in so you can see what effect each change makes. I'm not sure you'll need...

Yep, I agree. Buy both a 140 & 145. They're cheap and then you'll have a range of jets. Lots of info on this site on how to jet properly, so put them in one at a time and follow the sticky's and you'll be fine. 4-strokes are rather forgiving with the jetting so you don't have to be perfect...

Depends on what was done on the original install of the dial-a-jet. Generally, the instructions call for a much leaner main jet so your likely gonna need to go up 1-2 jet sizes. If it were originally jetted to sea level you might only need to go up 1 size. If it were jetted to 7k' then you might...

Curious if anyone has modded a 90-95 cdi to work on an 87? The part # prefixes are different (1UY-85540-20-00 vs 3GD-85540-20-00). They do have different plugs, but appear to have the same number of wires. I imagine the timing curve may be a little different and the timing would probably need to...