Background:
* All restrictors removed
* Airflow increased with opening filter box
* Stacked pilot removed
* Main increased to 67.5
* Compression 80lbs - good for 5.6:1 compression ratio
* Good spark
* Carburetor rebuilt - this is where I think my problems lie...see below

Results
Pretty awesome. I am 190lbs and I have to tap the brakes to make hard turns where as before I never let off the throttle. I need to carry my gps to clock it but guessing she is making close to 20mph.

Initial Start
In order to start, I put the petcock on the prime position and choke it. It is a little hard starting (10-15 pulls). Once started, it will usually die out and restart on next pull until it catches good. Let it warm up and everything is ok.

After Stopping It
I see fuel overflowing out of carb a little bit. The only way I can get it to restart is to drain the bowl and go back through the initial start procedures. If I do that, I can get it going again in about 10-15 pulls with in prime position with choke on and then switch petcock to on position. After that, it runs good again until I stop it...then must repeat procedure.

Other Info
When I disassembled the carb, I found a tiny oring wound up in the spring that is inside the pilot air screw hole. it could not have been doing anything as it was twisted up in the spring. There was no oring on the throttle stop screw. In looking at the parts diagram online and also my service manual, it shows no orings for either the pilot air screw or the throttle stop screw. What was this oring doing in there? I did not reinstall it when I rebuilt carb.

My Suspicion
Maybe my float is set improper. I have the specs on it, but it is very hard to measure with out the right tools. When turned upside down should it be basically level/parallel with the carb body or do I need to get it measured?

Am I on the right track with my suspicion? Any other thoughts...and what about that weird oring?

PS...you guys have a great forum. I have been working on this 4 wheeler for a few weeks now and this forum has been very helpful. Getting the main jet size up to 67.5 from the stock 55 was a huge help.

 

Had almost identical symptoms as you it baffled me for ages but yesterday I think I solved my problem the vacuum pipe was missing of mine replaced it and now it's running perfect and starts 1st pull now 9 out of 10 times without any choke so check the little vacuum pipe has now come off your

Hope this helps

 

I don't think 80 comp is that good.
I don't understand why you have to switch to prime to start.
Hope that helps...Lol