Frank Angerano

I would go the simplest route first and change the starter. I hate to say that because i like to verify what the problem is so your not wasting money but its hard to say at this point. Im assuming there is no pull or kick start to try and see how hard the engine to start that way ? Just a though but did you do anything to the atv before this happened like oil change or anything else ? The oil level is proper and not over filled ?

Spark plug is on top of the engine. You will need a deep socket to remove it. It has a black wire going to it.

Its in the right way and it looks primed to me. I would try the air restriction method and see if it revs higher. Just trying to rule out any kind of rev limiter that might not be working if your atv has one. Also try making an adjustment on the air/fuel screw.

Put the choke at half way after its warmed up OR try and cover of the intake on the carburetor halfway with your hand and see how it throttles up. If it revs with a little restriction of air then its obvious that there is a fuel shortage happening someplace within. By creating an air restriction allows for a better fuel mix and that allows the engine to rev. Are you 100% sure all the jets are back where they belong ? Also is there a good flow of fuel from the tank? No blocked fuel lines or petcock on the tank?

No problem brother keep us posted.

Def a good project! Nothing better then bringing something back from the dead. Nice work so far.

Ahhhhh ok i didn't realize you changed the battery. So yes see how it cranks without the spark plug. It really can only be a few things. The starer and or brushes inside of the starter. Or the decompression weights inside the top of the cylinder head on the cam. Sometimes the small springs on the cam weights come off. But go the starter route first. You can pull the starter off and bench test it also if your handy. If you pull the spark plug out and it still had trouble cranking then it's definitely the starter.

You can only do that jump for a second. Otherwise you will get the marks and possibly weld the wires to the nuts. But heres the thing, before all that pull the battery and run it to the local auto store and have them do a load test on it. Its free and will tell you if its good or not. But for now try this. Pull the spark plug and see how it cranks.

What about when you slowly accelerate? I had this problem on my Mojave but i put the two jets in the wrong spots since they are threaded the same. (Pilot and main). I don't think yours are and by the looks of the way you took it apart and numbered the jets on the cardboard i don't think its your case. This is usually a problem that happens when fuel is restricted making it into the main jet as you accelerate.

Definitely going to get two out of them. Lets get some blue canvas tarps up over the openings and a wood burning stove in that barn!

There should be one by the battery. There is a round small relay. Usually right next to it is a fuse. Take a few pics and post them, we will point it out if its there. On some of the smaller atvs it different. I haven't looked at the manual but it should be there. Have you located that fuse #3 on your diagram? And lastly some of those bikes had the emergency rip cord to shut it down in an emergency if you fall off the atv as well as a brake switch where you have to pull the brakes in to start.

Ok I thought you meant melted or burnt up. It's most likely something simple that was overlooked on the reassemble process. Take a look for that fuse i told you about first and then go back over your work step by step. Im thinking a wire got pulled out of a connector someplace. Double check the kill switch and ignition as well.

Fused together? Can you post a picture of the actual wires ? Nothing should be fused together unless there's a short someplace or the battery was connected wrong. There is sometimes a fuse next to the start solenoid that could be blown.

Hey @Chris2018 haven't seen you post in a while. Whats going on with the top end ?

Good stuff @Dra O Cant wait to hear that thing go! Good luck.

Agreed! I was just able to download as well. I am now able to open videos that i could not before on my phone! Sweet!! So it could be a sluggish starter. I don't want to throw any major suggestions out there but the decompression/compression release could be having a problem. Go the simple route first and make sure you didn't get a skunk battery. Maybe a dead cell inside from the factory, it happens. Check all wire connections like i mentioned earlier so you can eliminate any of that.

Hey guy welcome to Quadcrazy. Do you hear the solenoid click when you press the start button? If so great, take a tester or test light and put it on the wire on the starter that's covered with a small rubber boot and press the start button, if you get 12V then its a bad starter or brushes If you get no click then do the following: Pop the seat off you will see the red wire coming from the battery to a starter relay/solenoid. The solenoid has two wires bolted on it, one from the battery and the other goes to the starter. There is a small fuse next to this solenoid in a rubber cover that holds the solenoid. Check that fuse first and see what you find. You can jump the two wires together for a second ONLY A SECOND and you should get a little spark and the engine should crank. If it does not then its one of two things most likely. A: starter is bad B: starter brushes are bad. Both inexpensive to replace. My guess would be brushes. Before you start taking things apart first loosen and retighten the wires on the starter and the relay and check all grounds.

I don't believe that hose goes anywhere. It should just be a vent hose that mounts someplace along the frame right where the bottom of the gas tank and seat meet. Some of the Suzuki models had a vacuum line that works the fuel pump but I'm not 100% sure on your atv. If the gas line goes from the tank right to the carburetor then it's gravity fed and no pump should be on the machine.

Welcome to the crazy Quadcrazy forum!

Looks a bit high to me i would drop it a hair to be safe.

So when that line is even with the carburetor it shuts fuel off?

Looks better.

Nice work brother, cant wait to see how it goes. Keep us posted.

Yes it most likely did and leave it be !! I'm confident that Mr. Gold jet has cleaned all parts of the carburetor and shes ready to roll. Double check your float level, slap that puppy back together and fire this thing up! Where are you going to set the air/fuel screw at ?