200E carb issues

[saturnthegiant]

Hi I have a 83' 200E. A few months ago I had a problem with gas dumping from the carb, which I assumed was a sticking float valve. I have taken apart the carb and cleaned it and replaced most of the jets. Now I have it back together and am having a couple of issues: the engine is hard to start, like not getting enough fuel. When I do get it to start, I get a very high rev with very little control from the throttle. Any ideas?

[H2Sbass]

Sounds like maybe your slide is stuck or sticking. Possibly not aligned properly ? Check to make sure the needle is not bent and is entering the needle jet properly. Also, check for air leaks in the intake, they will cause it to idle very fast and unstable.

[saturnthegiant]

Yeah i think you are right. I'm going to inspect the throttle setup this weekend and see what's going on. Also, there is a tube missing, broken off. It's kinda behind the choke lever. I have the fuel tube, the overflow tube, and the other is missing.....what is it and where does it go?

[kb0nly]

Sounds like you put the slide in wrong, make sure its oriented right, it can go in two ways, but only one way is right so that it slides all the way down. There is a diagonal notch on one side of the slide that goes towards the idle set screw, the other side has a long slot and rides on the pin in the carb bore. If you put it in wrong it wont go down and so you get a high rev and also little throttle response because its held partially open.

[saturnthegiant]

I may have put the slide in wrong....it seemed like it went in all the way. Guess i need to see if the needle is sliding up and down. Any ideas on what the tube on the carb is?

[1985BigRed250ES]

its just a vent. none of mine have a hose on that vent. they are all rotted off. they work just fine with no hose. it just hangs off the carb.

[saturnthegiant]

Ok thanks a bunch!

[saturnthegiant]

Well, i'm at a loss. I've worked on this carb all evening, I have the slide in correctly, all the way in, the needle and clip seem to be in correctly. I'm still getting a high rev with very little throttle response. The engine revs down a little with the choke open, but if I close the choke, it revs really high. The air intake doesn't seem to have any leaks. Does anyone have any suggestions?

[saturnthegiant]

I worked on this some more this morning, the throttle is sliding all the way down into the carb throat. I even changed needles to see if that helped, set the clip to 3rd notch, not much change. I've gone through every jet and cleaned them, and tried to set the pilot screw according to the manual. I can get the engine to idle more normally with the choke closed, but once I open the choke it revs back up really high, no response from the idle screw. The intake boots and everything seem to be ok, no leaks that I can find. The only thing I haven't changed is the needle jet, I don't know how to get it out, but I have a new one if anyone could tell me how it comes out. I'm about out of ideas, I guess the only thing left is to get a new carb.

[saturnthegiant]

Well, I walked away for a while and watched a couple of youtube vids to see if I was missing anything, and I thought I would tackle it again. I've shot a whole can of carb cleaner through every orifice I could see. This time I got the old needle jet out and replaced it. I also cleaned and put in the old slow jet, it had bigger holes in it than the new one. I checked the pilot screw once more, replaced the little washer, o-ring, and spring. The throttle assembly is seated in the right way and the slide seems to be working great. I put a new o-ring on the side that attaches to the engine. Same result, high rev with choke open and closed. Airbox and boots all sealed good and tight. I'm at my wits end. I tried not to give up, but I don't know what else to do. This carb was fine until last year, the float valve started sticking and dumping gas. I ordered a carb kit but never got around to working on it until now. The float valve seems to be functioning ok. When this revving issue came up, I just cleaned and put in the old parts again. It makes no difference, old or new parts. I even checked the throttle cable up at the thumb throttle box, seems to be fine and not binding up. Does anyone have any experience with the Ebay carbs? They look to be the most inexpensive route. I guess they are Chinese carbs?

[kb0nly]

The only suggestion i can make at this point after reading your posts, check the intake tube between the engine and the carb VERY closely. You replaced the o-ring on the intake to the head i see you mentioned, thats a good step they can leak. The fact it slows down with the choke closed would leave me to believe its getting too much air and revving up because its lean when you open the choke. The general causes there is a cracked intake or a bad o-ring on the intake to head connection, or a stuck slide in the carb. So ruling that out i think it might be time to toss in the towel and buy a new carb. But before you spend that money like i said just go over that intake tube good!

The chinese carbs on ebay are good in my book. I have one on my 200ES, put one on a 200M this year and a 125M also, none of them have been anything but perfect. When you get it though pop the bowl off, check to see its clean, i got a few of them that had what looked like casting sand or grit in the bottom of them. Also check the jet sizes, they don't jet them all right. You can use the new jets from the carb kit you bought for your original carb to rejet the new chinese carb if needed.

[CRAZY70MAN]

You may want to check your throttle freeplay. If it is way out of adjustment....it could make it rev as well as have little throttle response. Do you have a manual??

[CRAZY70MAN]

You may want to check your throttle freeplay. If it is way out of adjustment....it could make it rev as well as have little throttle response. Do you have a manual?? Make sure you have 3/16"-3/8" of free play at the lever. The adjustment comes from the top nut and guide on the carb. Go to kbonly's link above in his avatar and download a manual if you need. one. Are you sure you have the slide and spring in correct though? I would check again.... Good luck

[saturnthegiant]

Yes I have a manual. I've gone over that slide and spring a hundred times....i'm certain I have it in right. I'll check the throttle freeplay and the intake tube. I didn't take the intake tube off but just inspected it by looking and feeling, there could be a hidden crack or something though. Thanks for the input fellas, I really appreciate it.

[H2Sbass]

One way to check for vacuum leaks is to have the engine running and hold a lit cigarette near various places on the intake manifold. Look for smoke being sucked in anywhere there is a leak. People also do this with carb cleaner/ether, it will rev up when it sucks it in through the leak ( PSA, BE CAREFULL if you use this method. You are spraying flammable stuff at a hot engine)

[JustEnough]

I just solved a fast idle problem on my 83 ATC200. It turned out that the cable housing was not seated into the ferrule at the top of the slide cap. It took me a while to figure out because the throttle seemed to be moving properly and it was down enough to get the cable end onto the slide. From now on I will slide the rubber cover up enough to see that the cable housing is all the way down in.

[kb0nly]

What i have done to check for leaks on these intakes is to take my propane torch, just crack the valve open till i can smell a bit of propane and hear a faint hiss, then with the motor running you put that unlit propane torch tip around the intake and the intake to head flange and see if the engine changes speed. If it does then its sucking in the propane and burning it. I learned that years ago from an old mechanic that used it to check for vacuum leaks on cars, quick and easy way to find a bad fitting or cracked hose thats sucking air.

[newfiebullet]

try letting your throttle cable go from the throttle and see if it helps, i had a bad cable and had a bunch of trouble, did that to find it idled nice and consistant.

[saturnthegiant]

I just solved a fast idle problem on my 83 ATC200. It turned out that the cable housing was not seated into the ferrule at the top of the slide cap. It took me a while to figure out because the throttle seemed to be moving properly and it was down enough to get the cable end onto the slide. From now on I will slide the rubber cover up enough to see that the cable housing is all the way down in.

This. I pulled the rubber housing up and the cable housing was free, not letting the cable seat all the way. I screwed it in and wahlah, all that was left was fine tuning the idle. Also today I replaced the headlight, cleaned up some of the wiring to the headlight/taillight, and got the electric start working good. I enjoyed a nice ride around the yard today, tomorrow hitting the backroads. Thanks everyone.

[newfiebullet]

good to hear, now have some fun :)

[kb0nly]

Awesome good to hear it!! Have fun, be safe!