As far as the petcock goes, I found a spare in my parts collection! So I swapped them over, also I took apart the old one (1 screw) to find it's missing a spring and the value definitely doesn't close. The new one ACTUALLY shuts off the gas





This has literally got to be the best carb cleaner on earth right here made by CYCLO, high pressure, very effective at decinigrating gum compared to many others I have used.



Here are the old gaskets and parts next to the new ones (minus the old pilot jet because I lost it)




Did not look that horrible to begin with:




After rebuild (all you can see here is the main jet and 1 gasket)

 

Update to post #51 about the engine knocking
I drained the gear oil and then realized I have to drain and remove the coolant system before I can access the clutch so I did. Do you think this antifreeze is bad or could have been changed sooner? It seems to be more clear at the bottom and thicker toward the top...



I noticed another issue though, on this cover to a compartment that I can't see what belongs in it on the schematics, there is a crack on the corner of the cover plate probably from the chain rubbing. What belongs in there?




On the other side of it there is a rubber grommet with holes, were there suppose to be wires going through this grommet or something?

 

It's a blank.
nothing goes there.

 

There's just an unused empty compartment in the engine? WTF

 

 

Well I guess I will make use of it, new stash spot but seriously was this block used on another model where the compartment WAS used, does anyone know anything about that?

 

the engine on the 85 and 86 is actually off of a dirtbike and that engine compartment is where the tach and other wiring accessories come from. they eliminated it to put the engine on the quad. your basket case is in pretty good shape. when i bought mine it had been raced hard and the frame was broken in 4 places but it had potential. and when it was finished it was very reliable and fast with lots of torque. i just traded it for a dirtbike with a title that im making street legal so i can ride it in the national forrest and not get in trouble(another story).

 

Woa, thanks for filling me in! Everyone tells me to get the 87' motor. That sounds pretty interesting to me, I'm an Arborist.


I took apart the engine today, did I mention how STUPID fillips heads are on something like this! I am replacing ALL of them with a allen wrench head style bolt. They stripped out and I had to drill them out, then smash a torques head into them and ratchet them out I believe they might have been thread locked.



I first saw the metal shavings and kind of cringed but turned out (so far) not to be too bad.




The red arrow points to the problem, which shaft/gear is this anyway? I'm guessing the crank balancer and gear?



Appears the nut spun off the shaft and was bouncing around between the gears allowing this gear to have play. I'm going to have to remove the clutch basket to see what is damaged or missing and replace the nut.

 

yeah thats your crank balancer. make sure it lines up correctly with the marks when you put it back in and use a drop of lock tight on it

 

the balancer driven gear
assy nut.

try phillips head & torx head
LOL