Picked up a Chinese Quad... New Project

[j.concepcion54321]

Hey guys,

Its been a while and i bought this quad a few weeks back. It has 3 bad tires, 2 are just slow leaks and one has a hole in it which i just plan to patch up and ride as is. They hold air for about 2 days before starting to leak so i think theyll hold up for a little while. ATV also needs a new master cylinder and brake lines. I was originally told that the kickstart gears needed to be realigned but after taking off the cvt cover i found out that it was total BS just so they could make a quick sale. They had welded part of the kickstart into the engine to make it look like it worked and temporarily have it working as kind of a quick fix. i took all the kickstart stuff out and hooked it up to a battery to try and get the electric start to work. i had no luck there. After taking off the plastics i realized that the wiring was all chopped up as well and that it was all jerry rigged like the rest of the bike -_-. At that point i lost hope and just covered it up.

Yesterday i took it out to mess around with it again. I found the wires that go directly to the starter motor and hooked it up to a battery and it turned overr so then i shot some starting fluid into the carb and it started up and ran for a little while. I had the gas tank hooked up but it didnt seem to be taking it in. Also since it has an electric choke i think that not having the wiring properly the chokes not getting taken off which is causing the engine to suffocate, shut off and not run for more then a few seconds. Another problem is that i dont have a year or a model to go off of. I was told that it was a 110cc chinese quad from 2003. but after some research they dont make 110cc gy6 style engines so im up in the air as to what this engine really is. I know its a gy6 clone and im guessing its a 150cc because of its size and the carb thats on it with the electric choke. im hoping one of you guys can help me with that using the pics.

So basically the parts i need are...
-Wiring Harness
-Tires or a patch
-Master Cylinder
-Brake Lines
-New front brake pads(They dont come close to locking up the wheel. can these be adjusted?)
-Battery
-Fuel Line.

I found this website which looks to have what i need
Wiring Harness:
http://www.scooterparts4less.com/web_gas/ATV_GY6_150cc_WireHarness.htm
Brakes:
http://www.scooterparts4less.com/Moped_Web/Moped_Master_Cylinder.htm (The last one at the bottom is the one im looking at)

and then the other parts ill try to find locally. What do you guys think? is this a trustworthy place to buy from? Also is that wiring harness going to work for my atv and the engine that it has?

Heres some pics:

And this is one of the night that i got it with me on it for size comparison. Im 15 and 5'9"

These pics were taken from my cell phone so theyre not that great but you can see what im dealing with. It may sound like a lot is wrong with it but i found it a steal at 60 bucks. Let me know guys. Thanks for reading this uber long post.

 

[OzFab]

As far as the wiring harness goes, is it all there? If so just do some searching & rejoin wires of the same colour; shouldn't be too difficult.

 

[jamyers]

Without the body panels, that looks just like the two Kasea ATV's with Xingfu 150cc GY6 engine I'm working on! There should be a VIN on the frame somewhere, mine are under the seat just above the airbox.

From what I've found, Kasea wiring diagrams are pretty much non-existent, but don't worry - Chinese GY6-powered ATV's are pretty generic, I found a couple of diagrams that work online by searching "GY6 wiring diagram". When I get home I'll dig up the one that worked best and post the link here. Hooking up wires by color-matching may or may not be a good idea, I've got several connectors that change wire colors - likely due to a replacement part in days gone by, but I'd be careful.

For $30 that harness looks like a good deal to me, I'd ask if it comes with a wiring diagram (but get it anyway if not). I haven't bought from them yet, but they look reputable and I'll likely get some stuff there in the future. Another decent-looking parts source is www.motopartsmax.com, I just ordered a brake-light switch from them. Looks like these ATV's are so generic that everything is available online (yay!)

The brake cylinder looks like a deal as well, especially if yours is broken or truly toasted (ie, scored inside bore). Is the rear brake hose physically damaged?

The front brakes are mechanical-pull drum brakes, very adjustable. Halfway down the cables there are some threaded adjusters, as well as up on the handlebar there is another (I'd use the lower ones first). If they won't take up all the slack, I'd pull the big hub nut, remove the tire/wheel/hub and look at the brake shoes. Again, they're readily available online from what I've seen.

I wouldn't worry about the kick-start, a local guy who works on these things told me that they're pretty much useless unless the engine is completely warmed up. One of my ATV's is missing it's kickstart, and I'm not planning on replacing it - the electric start kicks it right off even when cold once I cleaned the carb up.

I'd STRONGLY recommend pulling the carb, fuel tank, and cut-off valve, and giving them all a thorough cleaning - modern gasoline turns to varnish in a month, and those carbs have some REALLY tiny passages that are just about guaranteed to be plugged. Fuel hose you can get at any auto parts store. These carbs have a funky "choke" that's not really a choke, as you've undoubtedly found if you've searched the internet. Boiling lemon juice is your best friend...

For fixing the tires, Wal-mart or any auto-parts store ought to carry a patch or plug kit.

Check out my thread here for my story, and I'm glad to help anyway I can.

I'd say that for $60, you did get it for a steal - good score! Even better that they thought there were jacking you on the kickstarter deal...

 

[jamyers]

Here's the most useful wiring diagram I found. from over at Steele Power Sports:
http://www.steelespowersports.com/upload/BLADE 150 WIRING[1].jpg

Looks like you can ignore the horn, turn signals, and headlight circuits. Some of the wire colors weren't exactly the same as mine, and my green wire coming out of the stator dead-ends at a connector, and my "safety switch" in the start circuit is also the brake-light switch, but otherwise it's good. Lots of good GY6 info over at the Buggy Depot.

 

[j.concepcion54321]

As far as the wiring harness goes, is it all there? If so just do some searching & rejoin wires of the same colour; shouldn't be too difficult.

i messed with the wiring today and it turns out that im gonna need a new one. After crunching some numbers i found out that the atv is gonna be kinda pricey...

60- what i paid
10- tire patch kit
30- wiring harness
25- brake kit
25- engine shrouds and plastics (all are destroyed leaving flywheel exposed currently)
30+ - it may need a new carb because this ones not taking in gas ( it may just be a simple cleaning but im gonna ad this to the list any ways)
5-spark plug
15- paint
20- for misc. things that i have written down but cant think of atm.

total of aprox. $220 for a chinese atv. This is assuming that theres nothing else wrong with the engine if so then who knows. Im thinking of just taking a day to clean it up and then spend a few bucks on some paint to make it look nice then sell it as a project. In my CL someones selling a similar one not running with no plastics for 150 so i think that i can easily get that or around 175. Using that money and some that i have i can get a dirtbike which ill be more suited for, will be a name brand, and i can use in more areas and for a longer time.

EDIT: and thanks for all the helpful info Jaymer

 

[jamyers]

You're very welcome, and good luck on it - keep us posted!

 

[j.concepcion54321]

Yeah, ive got a serious problem. I thought i was gonna sell it so i decided to pretty it up and i painted all the plastics red and i filled up all the tires and made it look nice and then afterwards i didnt want to sell it anymore! haha. so im gonna end up keeping it.

I took off the airfilter today and i stuck my finger in the carb and messed with the choke myself. i was able to hook up a battery directly to the starter motor, and get her to start up and run. SHE SOUNDS LIKE A BEAST!! and revs up really high. i think the oil is bad though because its smoking alot for a 4 stroke. also theres oil around the muffler on the engine so i think its overflowing. im gonna drain it and put in some fresh oil to see if the problem goes away.

I decided that since the carb is my problem not really the wiring im gonna leave the wiring as is and just buy a new carb with a manual choke. This way i get a nice new carb that doesnt need cleaning(this ones dirty and wont take gas) and i have the manual choke so itll stay running good. im still looking around to find what size carb i need, anyone know what the carb size is for a 150cc gy6 engine?

 

[j.concepcion54321]

im thinking of getting this carb, http://www.ebay.com/itm/Carburetor-...es&vxp=mtr&hash=item3369ebfd63#ht_1557wt_1163

how would i be able to adapt it to the old mount? this carb has like the flange with 2 mounting holes, but the other one just has like a hose that goes to the intake and is then tightened around the outside.

 

[bighead]

What about the 70's 80's yamaha dt100 dt125 or the gt80 enduro type carb?

http://www.ebay.com/itm/Yamaha-DT10...Parts_Accessories&vxp=mtr&hash=item19cfd88efd

I have both the gt80 and the dt100 carbs on hand. I can take some measuring for you if you find a deal. Nothing like being sure they will fit.

I have the gt80 carb now that I am not using. I tried cleaning it a few times and never could get it to work right. I changed out the carb and the bike ran well. If you happen to get an gt80 carb you can have this one for parts. When I originaly cleaned this carb it was full of white crystal crap. Wierd stuff I tell you. So who knows what going on with it. Good parts though.

 

[jamyers]

im thinking of getting this carb, http://www.ebay.com/itm/Carburetor-...es&vxp=mtr&hash=item3369ebfd63#ht_1557wt_1163

how would i be able to adapt it to the old mount? this carb has like the flange with 2 mounting holes, but the other one just has like a hose that goes to the intake and is then tightened around the outside.

Stock GY6 carb doesn't have a "choke". A choke plate on the intake side of the slide would'nt work anyways because of the design of Constant-Velocity carbs. These CV carbs have a "fuel enrichment circuit" that's controlled by an electrically-heated 'solenoid' that admits extra fuel/air on the engine side of the throttle plate when it's cold. There are "manual choke" kits for sale and you can make your own or add a primer bulb, but really what you're doing is manually controlling the "enrichment circuit", not choking it (not trying to be picky/technical, but there is a significant difference). I'll likely be doing one or the other of those in the near future as I'm not sure mine is cutting off as it should).

If you want to go to a slide-type carb like that one, make sure you've got the room above the carb for the throttle cable - it comes straight up out of the top of the carb instead of hooking to the side.

I've got one of those ebay PZ26-type clone carbs still in a box, haven't decided which engine I'm going to use it on yet - if you need any measurements let me know. To use it, you'll need a throttle cable with a tiny ball on the carb end, and either a new manifold to bolt the carb to, or an adapter (if you've got the room) - all of which I imagine are available online, but... I still think that you'd be better off (and ahead money-wise) if you'd give that carb a good, thorough cleaning. You can spend a lot of money and time on new carbs, adapters, etc when the end result really isn't any better than original. The original carb is hard to beat, imho.

I'm curious about something else, though. You mentioned that the engine revs high, but on a GY6 w/ CVT the engine won't rev without trying to turn the rear wheels - did you have it on a jack, stand, or have the CVT belt off?

 

[j.concepcion54321]

I had it on a stand and the wheels were spinning. The cvt works as it should on mine. I think I have enough room but ill have to double check. And I'm not trying to get a new carb to avoid having to clean this one or whatever its just that I need one with a manual choke to get it to run right. Since my wiring is messed up the carb doesn't get the power needed to run the auto choke so I can't get it to stay running. But with a manual choke all I have to do is crank the engine, let it start and then take off the choke and it will run good. That's why I'm looking into getting that carb shown above. I found a kit online that was a carb, intake elbow, and airfilter for like 50 bucks and I may just get that if the intake is the same.

Anyone know if a 5hp tecumseh carb would work on this? Just curious cause I could always go that route and use one of the carbs I have here at home.

Big- do you think you could get me those measurements? Also do you by any chance have any other carbs in your massive parts collection that are like the one I showed with a 26mm intake?

Jay- would you consider selling that carb that you have? I think an adapter could be made to work, like a tube that fits into the intake and then a flange on the end to attach the carb to.

 

[j.concepcion54321]

I had it on a stand and the wheels were spinning. The cvt works as it should on mine. I think I have enough room but ill have to double check. And I'm not trying to get a new carb to avoid having to clean this one or whatever its just that I need one with a manual choke to get it to run right. Since my wiring is messed up the carb doesn't get the power needed to run the auto choke so I can't get it to stay running. But with a manual choke all I have to do is crank the engine, let it start and then take off the choke and it will run good. That's why I'm looking into getting that carb shown above. I found a kit online that was a carb, intake elbow, and airfilter for like 50 bucks and I may just get that if the intake is the same.

Anyone know if a 5hp tecumseh carb would work on this? Just curious cause I could always go that route and use one of the carbs I have here at home.

Big- do you think you could get me those measurements? Also do you by any chance have any other carbs in your massive parts collection that are like the one I showed with a 26mm intake?

Jay- would you consider selling that carb that you have? I think an adapter could be made to work, like a tube that fits into the intake and then a flange on the end to attach the carb to.

 

[jamyers]

...I found a kit online that was a carb, intake elbow, and airfilter for like 50 bucks and I may just get that if the intake is the same.

Anyone know if a 5hp tecumseh carb would work on this? Just curious cause I could always go that route and use one of the carbs I have here at home.
...
Jay- would you consider selling that carb that you have?
...

OK, I'm with you on the manual control when cold-starting, I'm prolly going to do one of the diy versions I mentioned above.

If the kit's manifold's internal passage is the same size or barely smaller and its bolt holes are close enough, $50 for all that sounds like a decent deal to me, assuming it'll physically fit in there.

I'll bet the tecumseh carb will work, only thing is how to install it? But then, that's the fun of diy!

I'm going to hang onto my carb, I'm thinking of taking our Briggs 8hp, going governor-less, and putting it all on a yerf-dog with CVT....

 

[j.concepcion54321]

ordered these parts for it tonight... hopefully by next week shell be running...
http://www.atvpartsusawholesale.com/shopping_cart.php

 

[spyder1968]

i just picked up a baha 150 project myself. was thinking of putting a 270 cc clone on it just for the fun. the motor looks very similar except no kick start,( elect. start only) anyway.....the harness is all cut up or missing pieces etc but if you want to take a trip to new bedford you can have the engine and rummage through my" extra parts pile" if you need anything in it. i know the engine runs. was best friends kids toy.

 

[j.concepcion54321]

spyder1968: hey, yeah id be glad to go buy and take a look. Is this free?

On another note... I got the carburetor today but it didnt come with any of the gaskets so i gave them a call and they said they are gonna send them over in another package so now i have to wait an additional week or 2 to get them :toetap05:

I also got the new master cylinder and i was able to get it mounted but when i was bleeding it i noticed a tiny hole in the brake lines... JB weld fixed it so now im just waiting for some more time to go out and bleed it again. Also got a patch for the tire although idk if its gonna be big enough, thats another thing that i gotta go do...

AND the plastics for the engine were back ordered so i still have to wait a while before i get those -____- Waiting for parts sucks...

 

[spongerich]

We have a bunch of Japanese quads and dirt bikes and they all suffer from clogged up carbs on a regular basis... The passages in the jets are just really freaking small and the combination of dusty riding and gas sitting in them for weeks plugs them up quickly.

The good news is that it takes 5 minutes to clean them out. Remove the bowl and take out the jets (replace the bowl screws with hex bolts while you're at it). A little carb cleaner and a guitar string makes quick work of cleaning the jets. Re-assemble and ride.

If you're not going to ride it for a few weeks, it's a good idea to drain the gas outta the carb (or just run it dry) before you put it away. That definitely prolongs the period between cleanings.

 

[shakey0818]

Josh let me know what u would want to sell it for as long as u dont use too much jb weld to patch it,lol.I have an old re painted semi-assembled consession cart i could trade for it.LMAO

 

[spyder1968]

yes......free

 

[Jake.B]

If you say it smokes alot you may have bad rings/cylinder walls or valve seating.