I have tested alot more since my first post. I am hoping that this narrows it down.

I have test the entire ignition systems, coil, satter, pulse gen, and the wiring, all is good. I know now that there is no way to time these, but I was able to verify that the timing was correct. I have pulled the carb off and tore it down, cleaned it, no jets or ports seemed to be clogged. reinstalled it, and it still doesn't want to idle. Still runs smooth at higher RPMs. Seems to be a vaccum leak somewhere that I can not find. Does the O-ring from the head to the carb boot go bad very often? Right now its the only place that I could find or think of that would be leaking.

 

air intake tube

sounds similar to a prob i had. turns out a mud dauber had built a half dozen nest in my air intake tube (or whatever its called lol) and was restricting air intake.

 

Did you check/adjust the valves?

 

I ended up rebuilding it. After new jets and everything it was running good. The new issue is the muffler. While deep in a trail ride, I was runnly at about 3/4 throttle and something in the muffler feel apart. It started sounding like a jet plane. And I lost alot of power. After a quick and angry kick to the muffler it righted. Sounded good and I took back off, till I got to 3/4 throttle again. So I ended up baby it all the way back.

Is there a way to repair those mufflers? I replacement stock one runs about $300, and I was unable to locate a used one around me. If I went aftermarket, that would require me to rejet the carb. And I am trying to avoid that.

Thanks for any advice.

 

I'd say a baffle come loose and plugged up your exhaust. I've cut a few open and removed the loose baffles and welded them back up. They run alil load but work and sound good.

 

I opened up the muffler and sure enough one of the baffles was completely blown apart. and the middle one was broke in half. I removed all the loose pieces and wielded the middle one back together and closed it all up. Seems to runs pretty good, about as loud as it was before, but now nothing blocks the exhaust. It should last me till I can come up with the cash to replace it. Thanks for the tips.

 

So what about the dragging part? Was it the restriction inside the muffler? Did you check any of the brakes/ bearings?

 

The dragging part, I tore down the front brakes, and found that both the left side, pistons were rust frozen. I had to seriously work the drum off. I was able to clean them up and get them work smoothly again. However I think in the spring I will rebuild the entire front brakes.

The restriction was a large piece of the baffle was falling against the exhuast exit hole and just sealing it off completely. While we had it open we did remove anything that was loose and rewielded what we could to get it as strong as possible.

I have to say that I have worked on my cars and jeeps alot, but getting this fourwheeler has been a real learning experience. Thanks for all the input. I more then likely will come up with more questions or issues.