This HubPage will focus on repairing an old quad motorcycle (ATV, or four wheeler), this model is a 1986 Honda TRX 200sx. All the plastics have been taken off so it will look much different than another quad of the same make and model.

The instructions to this will apply to most types of small engine carburetors, excluding EFI.

I do not take responsibility for any harm done to yourself or property while repairing or riding your quad or atv - by reading below this line you comply with the statement.

First you will need a clean workspace with very good ventilation, the ideal area will be working outside and have a fan as you will be working with gasoline. All the following tools are necessary: safety goggles, gloves if you don't want dry skin or scratches, magnetic tray or bowl to keep bolts and parts, a Phillips and flat-head screwdriver, metric size 10 wrench, an oiling can or oil to loosen tough bolts, small can for fuel catch, carburetor cleaner and a bowl to sit parts to clean in, a set of small punches, pliers or vice grips for extra tough screws and a wire brush to clean parts.

Before we begin turning a nut or bolt - turn off the fuel line. For this model its near the carburetor, connected to the bottom of the gas tank. Disconnect the battery from the left rear side of the ATV and remove it. Get a small can and follow the drain line of the carburetor, place the can at the end of this. There is a small flat-head screw on the bottom of the carburetor on the right side, open this until fuel comes out of the drain line. If the carburetor seems to be losing more than a half cup of fuel, make sure the fuel line is in the correct OFF position.

Have your bolts and screw magnetic bowl or equivalent ready now

After all the fuel has drained remove the choke cable, it will be on the left side of the carburetor - this choke cable was broken so there is no information reguarding it. Grab your size 10 wrench and begin taking off the two nuts connecting the carburetor to the engine on the carburetor side - picture shown below. Don't lose these.

Pull the carburetor toward the rear tires easily as to not break or bend the throttle cable cap on the top side, now remove the throttle cable, the top will unscrew - take note of which side had the longer slot on the carburetor, it will need to be installed just the same. Wiggle the carburetor out of the quads frame and head to your work bench!

Throttle needle shown below:

Get a punch a bit smaller than the float retainer and remove the retainer. Retainer circled in the picture below.

Don't remove the float too quickly, if the float needle is stuck it will break the float and you will need a new one. If it IS stuck maneuver the float itself away from the carburetor and needle, it should be very loose. If the needle was stuck try to maneuver the float itself away from the carburetor , it should slide off with ease. Now apply very little force and try to remove the needle from its seat.

Float removal pictured below:

Next remove the fuel jets circled below. Put them your cleaning bowl apply carb cleaner on these also. You will need to be able to dry them and see through the hole from the top to the bottom, and all the holes on the sides before they are installed again. I do not recommend cleaning them with anything that will scratch the metal. Fuel jets circled in the picture below.

Now we use a flathead screwdriver and turn the throttle position screw in until its fairly tight, write down how many full and partial turns you had to turn the screw head - down to the 1/4 turn if less than a full number. Now remove this screw and spring - keep them together and don't lose them. Part shown below:

On the opposite side of this picture where my index finger is you will see another flathead screw - this is your air/fuel mixture screw, turn it in the same way as the throttle position screw remembering the times turned. Then remove this screw and spring also, placing it in your magnetic tray. Next we sit the top of the carburetor inside the cleaning bowl also, cover with carb cleaner. Make sure to get in all of the small holes - if this part isn't completely clean your quad might not idle or run correctly!

Now let everything soak for a while - after one hour wash everything well and inspect for damages. If anything is damaged you should replace each part with new. If something doesn't come clean reapply carb cleaner.

Make sure fuel jet ways on the carburetor top are clean as shown below.

After everything looks good and clean inspect rubber seals. The float bowl seal shown below had to be replaced.

The seal will be brittle and fall apart if you attempt to remove it. Good seals will come out very easily.

Now that seals are inspected and parts deemed clean - assemble as you disassembled and test drive. Take it easy first so you know there aren't any major problems with the carburetor. If there are you may need to buy a new carburetor top as some valves inside are too small to clean.

Enjoy and check out the forums at the ATV links below.

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