[pst]

I have just got a free 1991 200d fourtrax and I want to just fix it enough to use around the place here I do think when I get ti running I would like to change the gearing to the lower side I can not find a going shop manual for free download and I do not spend a lot on this and it looks like the tires are going to be a big part

 

[Goober]

Lol common complaint is that these things aren’t cheap! It doesn’t run, you got it for free, and you don’t want to put much money in it. What’s your budget?

There are links in my signature block for the manual and parts suppliers.

 

[shadetree]

welcome to the forums. from what I am reading ? ^^^ your headed down a bad road !. dont half way fix it, and dont try to change the gearing !. if you dont know what your doing ?, then dont mess with what works !. fix it back like it left the factory, and leave it at that. do not start '' hacking '' things up !, if you do ?, you wont get much help here, all you will do is waste our time.

 

[mrbb]

I agree, if your not sure what your doing, fixing a older atv can be a sink hole for money!
altering it will also most times cost you more than just making it good again!

tires do dry rot, but many times you can find cheap used tries folks take off newer atv's to get BIG one's, BIG tires are the cool thing these days LOL

as for a free download service manual, there night not be any out there on this model/yr
you can try looking on Ebay for a used paper copy one!

if your also not into fixing things, maybe just sell it AS IS< and use the money there to help you buy something in better shape, or part the atv out, many times things are worth more in parts than whole!

 

[pst]

Thank you I will check them out My Budget is limited and just looking at tires would have blow it but I got some ideas I found tubes for em so we will see I am a fairly good mechanic and have worked on a few I spent 4 years keeping 5 fourtrax's and other ranch equipment running so I can do a lot but I can always use advise so thank you

 

[pst]

Well I want to change the gearing so it is on the low side because it will be used around the house / garden so speed is not a thing but towing might be As far as knowing what to do I took care of the old 3 wheeler's them the 250 foortrax and 300 fourtrax's at the ranch for a few years These guy's were used 7 days a week 10-12 hrs a day for months on end and all work on them was done of a night plus other work so I know what a sink hole it can be and I do know my way around I do want any and all advise and things to look out for . Right now I have found tubes that will fit the tires so I will try them I am just getting started but for the most part it is old but ok The tank is clean and I see not even a hint of rust so that is a good sign The battery is taking a charge it turns over ok and has compression. My plan is to check spark and get the carb off for a good cleaning the cables are in need of a good soaking The gearing is way down the road But I do like that it is a chain drive so that is easy to change If and when I do get it running ok I do know I will need to fab up a hitch for it and something like the light on the old 250 fourtrax that turned with the handlebars So first up is cleaning the carb make sure I have fire The one thing I do have going is I know the people who gave it to me and they said it was running when they parked it and it has sat for a year or two but I do trust them so it was running

 

[pst]

Thank you

Lol common complaint is that these things aren’t cheap! It doesn’t run, you got it for free, and you don’t want to put much money in it. What’s your budget?

There are links in my signature block for the manual and parts suppliers.

Thank you this is what I needed to help start can not say thanks enough you saved hrs of search time so now I have late night reading I do know when to bail out but the thing is even just the fenders and racks that are not cracked broken or beat up can be re sold on E bay or worst case is shoe in a different motor but I think this one will run for what I need It will never be more than walking distance from the house :| It will be pulling a trailer or hauling a sprayer But thank you again this will help
I will check in with updates and stuff I fab up if that's ok

 

[Goober]

YW very much glad to help.

Always buy OEM parts as long as you can and continue to ask questions.

the fuel tank looked good? Nice. Drain the old fuel out through the petcock and carb fuel line–get any solids outta there before you rebuild the carb. Is carb a keihin PD 63A?

Ok you saw it was chain drive and maybe easier to gear it down some. Best to also make sure the stock tire size is used–what are they 20 and 21 inch? That’s a limbo tire as low as you can go I believe lol!

The carb gaskets may be real brittle so here’s a shindy carb kit on fleabay. We have some great threads on cleaning carbs when you’re ready.

One last thing, best not to use a failed battery—it may kick start but if the battery won’t take a charge then you risk ruining the stator

 

[fishfiles]

Lower gearing : since you are chain driven , it would take a sprocket change , a bigger rear sprocket or smaller front sprocket or change both sprockets ---------I believe the way it works is you make a fraction of the front and rear sprockets , divide it out and that will tell you what you got now , Example 12/42 -- 12 divided by 42 equals 2.085 ratio , ----a 44 teeth rear /12 tooth front would put you at .2727 ----count the teeth on your front and rear sprockets

 

[mrbb]

I would suggest just replacing the fuel line its cheap, fuel sitting in lines a long time can case built up that will flake off when running and make a carb you just cleaned dirty
so for the small price and amount of line, just replace it and save yourself some headaches!

as for tubes, if tires are dry rotting, they won't be much help for long
look on local craigslist or local dealers for take off tires, many times they can be pretty darn cheap
and even used one's too!

as for changing gearing again, if your going to do so, when you change a sprocket your supposed to change BOTH sprockets as chain at same time, due to the fact the things wear into each other to seat, when you change just one sprocket or just a new chain, you will have excessive wear and tear on ALL things, getting you must shorter life of all 3 things!

 

[notagt]

I would run lol, good luck man.

 

[pst]

OK Good news and bad news Good news I got it to turn over and it fired eek so that is great The lights and switches work ( HI and low beam) the neutral and reverse lights work Now the bad news The tail light lens is broken:sad also both choke and throttle cables are frozen But the carb needs a good cleaning so they can soak at the same time, I do not think the battery is going to hold a charge so will look for a used one The tires are bad and will not hold air but I can get tubes and they might last for awhile Can anyone help me with someplace to find used ATV tires ?The chain and sprockets look OK just need a good cleaning and lubing. The muffler is broken off but it is there and not to rusted out so I think I can weld it back up The outer part of the muffler has a few spots that are rusted threw but I can skin that and patch it up I want to thank ya for the links for the manuals they will be a big BIG help and saved me hrs of searching I think the air cleaner is a lost cause but maybe not So the plan is to get the tank off and a good cleaning ( I do not see any rust in it ) Pull the carb and clean it and get the cables freed up so I can run if for a bit and see if there is anything else that I need to look at runt it threw the gears to make sure nothing is broken Then look into what to spend on what I do think I got lucky all the fenders are in great shape no cracks or broken parts ( except the tail light) even the flaps are good The racks are good no dents or bends so a good cleaning and some paint and there good So a few things like how do you start a thread?? I would like to post as I go along for a cheep bargain barn 200d fortrax restore and any ideas would be great as I go along thanks

 

[shadetree]

OK Good news and bad news Good news I got it to turn over and it fired eek so that is great The lights and switches work ( HI and low beam) the neutral and reverse lights work Now the bad news The tail light lens is broken:sad also both choke and throttle cables are frozen But the carb needs a good cleaning so they can soak at the same time, I do not think the battery is going to hold a charge so will look for a used one The tires are bad and will not hold air but I can get tubes and they might last for awhile Can anyone help me with someplace to find used ATV tires ?The chain and sprockets look OK just need a good cleaning and lubing. The muffler is broken off but it is there and not to rusted out so I think I can weld it back up The outer part of the muffler has a few spots that are rusted threw but I can skin that and patch it up I want to thank ya for the links for the manuals they will be a big BIG help and saved me hrs of searching I think the air cleaner is a lost cause but maybe not So the plan is to get the tank off and a good cleaning ( I do not see any rust in it ) Pull the carb and clean it and get the cables freed up so I can run if for a bit and see if there is anything else that I need to look at runt it threw the gears to make sure nothing is broken Then look into what to spend on what I do think I got lucky all the fenders are in great shape no cracks or broken parts ( except the tail light) even the flaps are good The racks are good no dents or bends so a good cleaning and some paint and there good So a few things like how do you start a thread?? I would like to post as I go along for a cheep bargain barn 200d fortrax restore and any ideas would be great as I go along thanks

go to the front page, find DIY, build section, open it, look to the top left, see that big ole button that say's '' new thread '' ?, click it, then enter the topic, make, model, year, or just model ( full model ), and start typing your post out, then hit submit at the bottom.

 

[pst]

no it will be fun for me and it is something to play with and will be very usefull if I get it going