200s carb problem

[85_ATC_200S]

Well i guess imma start from the beginning. I have an 85 200s. Last year in July it lost spark, i thought it was the stator, well this week i pulled the tarp off of it (it's been sitting since july in my shed) and a friend and i were gonnns fix it. I fixed the pullstarter and the spark plug wire (which turned out to be why it had no spark, now it has a ton) and we pulled it behind my bro's 3 wheeler. It sputtered to life but ran really bad. Figuring it was the fuel i drained the tank and the carb and filled it up. So we pulled it again and it sputtered to life once more, it still ran like crap. So i rode it into my shed and it died in a hurry. Figuring we need to clean the carb i looked down at it, gas was pouring out of the bottom overflow. So i turned off the gas and plugged the overflow with my finger and we drained the carb once more. Well i was taking off the plastic to get to the carb thinkin the floats were stuck and dropped the socket into the airbox. I heard a splash and looked in and it was full of gas. After draining that i had the cab off and the floats were fine, it was clean so i just blew it out and put it back together. I turned on the gas and wached the bottom overflow again. Same deal. Any ideas?

[bonkers_200s]

the over flow should have a screw above it, make sure that screw is all the way in, only back it out if you have flooded it, turn the petcock off, then open that valve.

But your float may be sticking, causing an actuall over flow, it's very easy too take the carb off, two 10mm nuts and the fuel line, take it off the intake, then take the bowl off, un-screw your jets, make sure they aren't clogged or tarnished up, if you dont have carb cleaner, I've used starting fluid, wd-40, kero. any of them will work, even hot water with dish soap will work, just make sure its completly dry before re-installing.

Turn the adjustment screws all the way in (under carb, and on the right side at the top.) take them out, 1 1/4--1 1/2, that should be a decent starting point, then fine tune it from there.

Good luck, 30-45 minute job.

[85_ATC_200S]

I know how to do all theat stuff, the screw is all the way in, did you read all of the post? lol i checked all of that, float level never changed, everything is great, it ran awesome before it lost spark, i need help figuring out why floats arent closing the fuel supply, they are all clean, the carb is spotless, they should be closing it, there is no fuel in the floats, so thats not it, it just doesnt make sense.

[bonkers_200s]

is your needle shot?

sometimes they get scored.

[bigredhead]

Is your choke stuck ?

[85_ATC_200S]

No they are bolth great. Is there a seal that could have gone out somewhere? If so is there anywhere i can get a rebuild kit?

[83185s]

maybe its that little black over flow needle in the bottom of your carb..they get worn out also

[bigredhead]

There are 2 overflow lines. a bottom one ( when you drain the bowl with a flat head screw ) and a top one when the bowl gets too full.

If it's pouring out of the top one, it's the float level or the seat... since the float was never touched,,, clean the rubber top that the float pushes up and the inside passage where it goes in.

If it's the bottom line spewing gas tighten the flat head screw on the bottom of the bowl a bit.....

as far as gas in the airbox goes, the only way it can get in there is when you block the top overflow tube and gas keeps going into the carb.. eventually it's the only other place it can go ! Or somehow on the compression storke the intake valve is not closing at TDC and gas it pushed out thru the carb and into the airbox...

Weird thought.. but since it sat there for a long time...... was it pure gas in the airbox or melted snow/water ...?

[Huffa]

The float needle may look clean but may very well be worn the slightest smidgen of a bit.

With the bowl off, did you actually blow air into the fuel line with your mouth (low pressure) and at the same time operate the float up and down? You should not hear any air leaking, hissing, (whatever you want to call it) from the float valve seat with the float up.

If not..........try it!

[85_ATC_200S]

There isnt anything coming out of the top overflow, it's the bottom one, the screw is all the way tight, so the only way gas is gonna be comin out of there is by way of that little coppert tube that goes from the bottom of the bowl up, which i figured meant the floats werent closing it and gas was gettin that high, it was pure gas in the air box, still havnt figured that out... man i hate this!!!! :cry:

[BIG BAD RED]

hate to tell it to you but pull the carb back off...take your floats out and look in the copper insert the float needle sits in...since its been sitting so long there should be a fair bit of corosion/gunk in there..get back to us when u check that

[HaggLE]

Another thing to check is to check that your floats havent changed from floats to sinks :)

Put them in a bowl of fuel for an hour and see if they dont start to sink. Otherwise check that the valve is shutting of as Huffa suggested. I think Huffa is on the money!

[85_ATC_200S]

Yea well i tore it apart again, the floats are closing it for sure i blew thru the gas line and closed the floats and it's air tight. So i put it back together and hooked it all up turned on the gas and waited awhile, the drain screw is tight, and after 5 min it came pourin out the bottom overlow, and i got mad and turned off the gas and put my tools away and went to put the seat back on and theres gas in the airbox again, never ran it this tome so it has to be runnin in there from the carb, im gettin too mad to be working on this thing i need to sink it in my lake.

[bigredhead]

ok.. just because i've had it happen to me before.. and i know this is STUPID..


but.

When you removed the carb.. did you remove all the fuel and overflow lines from the carb ? make SURE you have the fuel line comming into the proper inlet of the carb.

A friend of mine showed me how to rebuild them.. low and behold when he put it back on the bike.. it was doind exactly what you describe.. after taking it off and cleaning EVERY TINY LITTLE spot jet, float, etc...... and put it back on the bike.. i noticed one of the overflow lines was put on wrong and it was connected to the gas tank !!!!! causing gas to pour all over the place.

God was that ever dumb. but it happened.

If it's leaking form the very bottom bowl " Drain ".. you might have crushed the rubber o-ring in there...

Never quit... it's a machine.. there is always a solution !

[85_ATC_200S]

I bet thats wat i did
goin to check it out now

[bigredhead]

And. ?

Find a problem ?

[85_ATC_200S]

Yup thats exactly what happioned. Last carb i cleaned was ny friends 86 200x and the fuel line goes where the overflow is on mine, so i got confused, this would expalin the gas in the airbox. lol

[bigredhead]

I'll be waiting for my cheque !

Congrats.. how's she runnin ?