Frank Angerano

Hey @Steven Urban welcome to Quadcrazy. The second part you show in the picture is your starter circuit relay. It all starts from your neutral safety switch. It looks like its in bad shape but they still work in that condition. Anyway you should have 4 wires going into it. Light green, brown and two black ones. Here's how it works: the green wire runs down to the neutral safety switch on the left side of the engine right above the shifter. The brown wire is a 12v positive wire. The two black wires are what completes the start circuit when touched together. Here is where to start: take a jumper wire and jump the two black wires on the relay together and hit the start button. (Make sure the atv is in neutral) and see if it cranks. if so thats good. After that; Take a tester and see if you have 12v+ on the brown wire at the relay. If so then thats good. Now the green wire is simply a ground thats made when the atv is in neutral. That green wire has a device inside the engine that when clicked into neutral it grounds the green wire. So in essence the 12v brown on the relay and the green (ground) when put in neutral energizes the relay and brings the two black wires together and also brings on the neutral light. If you have no ground from the green wire then put a jumper from green wire on the realy to a good ground. If that works then the neutral safety switch is bad. That starter circuit relay is an easy find if need be. Do some of these test first and lets see what you get. https://www.ebay.com/itm/153882535043

Hey @Amboyjim welcome to Quadcrazy! Check the diaphragm on the fuel pump. If the diaphragm is bad and gets a hole in it the fuel gets sucked into the carburetor via the vacuum line and floods the engine and winds up getting kicked back into the air box. Also when you set the air fuel screw after the carburetor rebuild did you set it properly?

True but you gained a ton of knowledge and you cant put a price on that! Now you will be able to tear into another one down the road and know whats what. You don't forget things like that. It may take a minute or two to jog your memory but it will come back to you should you ever take another one apart.

Looks like you are strolling down memory lane tonight! Good way to close out topics though!

Another blast from the past! I too love working on things but love it more when you get paid!!

Dam @JacobSlabach this was a blast from the past post. $3200 was a good price for that bike.

Welcome to Quadcrazy! Nice machine! What year ?

https://www.ebay.com/itm/173886468514 https://www.ebay.com/itm/352811100486

Maybe but if the engine was running fine other then smoke and all you did were valve seals im a little stumped by the chain just binding up. That only happens when you are 180 out and a collision happens or no oil. Its just odd to me.

That sucks but have you found out why this happened? One would have to hope it was just a locked up chain. The only way to test the piston, valves etc for compression would be you have to fill that cylinder head with air pressure and see how it holds. Even if you have to rig an air compressor hose to the fitting from your leak down gauges that goes into the spark plug hole and set it to 90 psi and fill the head up.

Accidentally got the right one!! I would never be so lucky! Keep us posted on how it works out.

@Scott M agreed 100%

Wow!! I knew it, jumped. That chain looks fu****. I would double check the chain is free of any more kinks like the one you see and if any links are not moving well then replace it. Hopefully no damage to the piston or valves!!!!! Its a long shot but hopefully none.

Wow! Looks like an atv thats been on the beach! A lot!!

It all sounds logical and i agree with the valve slop being a possibility, a valve seal coming off will cause the fouled plugs. As far as compression goes i have a feeling it's a lot worse then valve slop and maybe a bent valve or something along those lines.

https://orangeimports.co.uk/collections/bashan-bs200s-7-parts Try that.

I have a friend that has the same atv. He keeps it running tip top. So far its still running strong.

Couple of ways to look at this. Double check timing straight away. When you reassemble the top end did you set the timing correctly? Ive done it before and found it 180 degrees out BUT I always slowly rotate the the engine without the spark plug in and feel for any hits between the valves and piston. So if you went ahead and cranked it right out of the gate and timing was off then you could have a cracked piston or bent valve. (worst case) So pull the valve cover off and get to TDC compression stroke and look at your timing, also look at your chain tensioner and make sure you put it all back right and that it had not allowed the chain to jump and cause the above possible damage. Have you checked your head gaskets and did you use quality gaskets?? Cheap head gaskets go bad real quick especially if there is a slight warp in the head. Valves: did you put the valves back where they came from? Each valve if using old valves should go back exactly where they came from. Valve seals, its possible one has come off? Pull the spark plug wire off after you have confirmed the timing is right and crank the engine and listen for air leaks. Spray windex on the top end and look for bubbles if you want. Spray around the head gaskets, loosen the oil fill cap and spray around that as well while cranking. If you get bubbles then there is compression leaking into the crank case.

Nice work and great job explaining the test results. Keep us posted!

Ok lets go through some steps and do a process of elimination thing. If your concerned or think its the carburetor then go through the manual, check the spec on the jets and the sizes and make sure everything is proper according to the specifications including the float height. Check the choke and make sure its not getting hung up or pulled in while the throttle is reving ? This way you will rule out the carburetor. Next would be fuel flow from the tank. Could be restricted or have some sort of vapor lock from the gas cap? Leave the cap off and see if it still gives you a problem After that i would look at the intake boot that connects the carburetor to engine and check for any cracks that may be sucking in air from time to time. A simple trick to test this is spray some carburetor cleaner around the carburetor while the engine is running and listen for any changes in the way the engine runs, lightly wiggle the carburetor as well to expose any cracks on the boot So after all this is done you will have ruled out any carburetor and fuel delivery issues. If that has not fixed the problem i would buy an in line spark tester and attach it to the spark plug and spark plug wire and see if the spark breaks down under a throttle load. Its about $10 bucks on Amazon. Get a tester and start to check the specs on all of the electrical equipment, regulator, stator etc. Even if you replaced them or tested to it again. Rule out all items electrically and write down everything. While the engine is running start wiggling the wire harness around and again listen for changes. After that the only thing it could be is tye cdi$$$$$$$$$ And that sucks!!!

Have you checked the gap on the pick up coil? I remember a post way back about a similar problem and it turns out the gap on the pick up coil was the problem. It ran great in place but after a load was put on it the atv it bogged down.

Was the new carburetor an oem or a cheap replacement? China carburetor?

Honestly heres my take. If its at the point where you feel its bad and a possibility that the tank my have skunk gas as well then pull the tank and clean the carburetor and tank properly. I've very rarely had luck by rotating and cleaning the carburetor in place. You only wind up pulling it all out again.

You don't have to take the tank off. Sometimes it makes life easier but it should be able to come off without taking the tank off. I like to loosen both clamps first. Disconnect the gas lone, pull the carb out so you can take the throttle cable and the choke cable off. Re assemble in the same way.

Your very welcome!