im having quite a few problems with the carburetor on my 84 200s. a while back i put a xr 200 camshaft in it and guted the exhaust. i did a plug chop a week later with a 107 jet, stock jet 98. it was really rich and that was the smallest jet i had so i orders lower jets. i plug choped with 105 and the spark plug was now metal colored. now i am at a 117 jet, the biggest i have, with the neelde jet the highest and the spark plug still looks just like it it did with the 105. this is really confusing me and i cant get it running rich at all ive been riding normally around and the spark plug is still metal colored. and i cant get it to idle right ive cleaned the carb several times and still nothing. i can turn the idle rpm screw all the way in and it will idle real low few a few seconds then die. other random times when i start it up cold it will idle real high, like 2500rpm. but then when running for a bit it wont idle. please help thanks jeff

 

Have you checked the compression?
As far as jetting goes, the plug chop isnt the easiest thing to do. There are so many additives in the gas , the plug chop can be hard to read. Your best bet is to use the symptoms to figure out the rich and lean. If pulling on the choke makes it run better, or partially covering the intake...then its too lean.
Heres a good article on jetting, and it has the symptoms of lean and rich.
jetting

 

well i got it for free and it smokes alot so i assume the compression isent very high. i had the engine apart and the ring gaps were about .40. but when i partilly close the choke it hardly runs.

 

i believe i found my problem. the needle clip position isent adjusted right.

http://forums.atvconnection.com/mess...did/342966.cfm