HeWasRidinDirty

Raw power would be a big bore 2 stroke on 2 wheels. That’ll make your sticker peck out!

Thanks for the help. This thing is going to be used for doing stuff around the property. No joy riding. LOL I have my fun on 2 wheels. The wife likes the quad riding. She has a Honda rancher that we bought new in 07.

Yup. Performed the tests and ruled out both ignition and relay switches. Turns out the problem was in the on/off switch. The old thing runs pretty good!

If I ground the green wire on the solenoid side of the plug and put 12v to the white wire that should engage the starter right?

Ok I have a solenoid and ignition switch on the way. The owner said he started it at one point with the key. When I got it, turning the key did nothing. No dash lights, nothing. If I turned the key on jumper the solenoid it would crank over.

So the white wire, coming from the ignition switch, when I turn the key to start, should energize? Or if I put power and ground the green wire that completes the circuit and the starter should engage? I’m thinking that the ignition switch might be the problem.

Ok that makes sense. I’m guessing the green would be the ground?

The one I need to replace has a 2 wire plug coming out of it. Searching eBay I see tons of them with only 1 wire . WTH???

Come on man!!!! LOL I mean after the flood of gasoline I plugged the stuff up and all seems good. I appreciate the feedback and the help. My experience with these types have been if they leak replace it. I never looked into how they work. So now I understand a bit. Still don’t understand the thinking behind using these type of prtcocks.

Again it’s not the needle/seat/float. Needle and seat are brand new, OEM, and the float is set at 13mm. And like I said, when hooked up to the auxiliary tank, zero issues. Here’s what I found yesterday. Yikes! That’s mostly gas, just from the engine. The bike holds 2 quarts of oil and I think I drained probably 3.5 quarts total out of it. So apparently at some point with the fuel tank connected it was leaking into the vacuum port on the carb. Cuz that is a lot of gas in the oil. I must have left the petcock in the PRI or RES position overnight or all day long or something. As I posted earlier the thing died on me and after seeing all of the gas in the oil I was kinda freaked out thinking that I ruined the motor somehow. I put some fresh oil in it and it fired right up and everything seems cool. I do have a new petcock on the way that doesn’t use the vacuum port.

That’s what I’m thinking of doing. I don’t see the reason behind the vacuum operating the petcock like that. Gravity always works. Anyway I got the thing back together plugged the vacuum line and capped the port on the carb. Went for a little ride, 2-3 minutes, and it was crapping out at WOT in 3rd gear. Then it just died. Couldn’t get it to start again. Checked the plug, it was wet. Spark is good, compression is good. I pulled the filter to look inside the intake and I see a bunch of oil in the airbox and in the carb. Is it possible that when the engine got flooded with gas that some seeped past the rings and into the crankcase? It happened 2 times, but I pulled the plug out and pumped the fuel out both times within about 15 minutes or so. The dipstick shows over full and it smells like gas. I’m assuming that nothing was damaged with the short ride time?

Well as I explained in the OP, with the auxiliary tank hooked up to the carb the bike runs great, zero issues.

Thank you for the explanation. My gawd, I haven’t been on here is several years, the freaking ads are off the chart! Anyway, so pic 1 is the ON position, and both fuel inlets are covered. So that’s where the vacuum comes in? I don’t see how it gets fuel, but it works somehow, obviously. The 2 pic is the PRI position and it opens up the reserve port. And pic 3 is the RES position and it opens up both ports but no fuel would into the carb supply? Couldn’t that vacuum be bypassed and would just have to treat the PRI position as ON and it would be drawing fuel, via gravity, but in effect you would have no reserve? I just looked up a $10 petcock and it only had ON/OFF/RES, so it looks like it deletes that vacuum thing.

I rebuilt the carb on said machine. When I hook up the auxiliary gas tank it runs fine and everything is cool. When I put the fuel tank on and hooked up the lines, it completely flooded the cylinder and even about an inch of fuel in the air box. I'm pretty sure that it comes from the little hose on the petcock and hooks to the top of the carb. WTH is that even for? I mean the thing runs fine on the auxiliary tank, so idk And on the petcock when it's in the "on" position, I get no fuel. The petcock from the bike I took it apart and checked out how it operates. The sharpie marks indicate how it really works. Now the other petcock w/o the sharpie marks is an old one that was leaking that I removed from a Polaris quad. It's exactly the same thing, except the small hose and nipple have been removed. I'm so confused, LOL

Ya, 90 bux for a t-stat! I remember when I was a youngin my Chevy trucks took a $5 t-stat.

I may try that. But it looks like there is no gasket on the housing but rather an o-ring on the t-stat. So, it may leak a little bit while checking it out.

A lil update. Warmed up the bike again and rode it around a bit, the fan came on again, but, I noticed that the upper hose that connects to the thermo housing is hot like it should be, but, the lower hose that connects to the water pump housing isn't hot. Barely warm. Maybe the stat is stuck closed???

My neighbor said that his atv would light up the temp light after only 5 minutes of run time. He wants me to replace the thermostat. So, I got it here and I'm checking it out, and I've warmed it up twice and ridden it around a bit and I get no temp light. The fan works as it should. I even unplugged the temp switch right by the thermostat housing and the fan continues to run. So, that tells me the switch is for the temp light? If that is so then shouldn't the light come on when I unplug the switch? Is there another temp switch that turns on the fan? Thanks!

This ^^^

So. thinking about this thing overnight. The cam chain is intact and the tensioner seems to be working properly. The original owner let the thing sit for about 15 years under a tarp. I was mistaken about the guy that I got it from. He did get it running for a short time, and it crapped out and he didn't figure out what was wrong with it. I'm wondering if the center intake valve stuck and got hit by the piston. I'm going to get a leak down tester today and see what the deal is.

I got this 660 a couple days ago. Apparantley, and older gentleman bought in new in 02, rode it a few times and parked it. It has 500 miles and 50 hours on it. So, a dude bought it cheap, and though he could get it running just by cleaning the carb, tank etc. Well, that was done, and it still doesn't start. So, I got it from the 2 nd owner thinking I can fix it. I started checking it out, cleaned the carb (the 2nd owner let it sit for some time too) and when I crank it, it sounds like it wants to start, it might even do a little backfire but no go. It's got spark, I changed the plug, however, the compression came in at only about 25-30 psi. Damn. So, I checked the valves and the intakes R and L seemed just a smidge tight. The middle intake, tho, had a big gap that I could see with the naked eye. So, I'm wondering if somehow that valve hit the piston and bent it?

I'm not kidding, but a week or so ago, at 4am I was awake (as usual) and thinking about this thing. It dawned on my to check the bowl vent tube. Yep it was plugged up. I cleared it out and away it went! Sometimes it's just a simple thing.

Its a 2006. Someone had the carb apart and it looks like the beat the fire out of it. The brass float, on one side, is kinda caved in, and the little tube that is connected to the choke is bent. LOL When it starts it doesn't smoke. I took the carb apart again and it looked like the float was out of adjustment. It was binding up when it went down so it wouldn't let fuel in. I bent the tab a bit where it seemed to move a bit more freely. I put it back on and started it, gas was coming out the overflow, but it still dies out. So, I wasn't sure if it was a fuel problem or something else. So I got it to run again and kept hitting it with a small shot of ether and as long as I did that, it would stay running. So, it seems it's def a fuel flow problem. I checked on ebay for a carb, but found nothing. So...

So the compression on this little quad came up to 90 psi. I squirted a little bit of oil into the plug hole and it came up to 110. Now, I'm having an issue with it not wanting to rev up. It starts ok, but if I turn off the choke it dies. With the choke on, it doesn't want to rev up. I cleaned the carb and replaced the pilot jet. Is the problem the compression, the carb, or both?

Yep. What a PITA! However a cordless grinder with a cut-off wheel works wonders! Got 'er done.