If you manage to find yourself an old AG200 that has been lying around in a shed for a year or two and you want to try and get it going, take my advice – don’t bother! Not until you have cleaned the carburettor out anyway. Unless the farmer who owned it was a maintenance ninja (um…yeah) and drained the fuel out before laying it up in the shed, then the carb will be a mess and even if you do manage fire it up, it will suck all sorts of rubbish into the engine. Read on AG200 ninjas…
First thing to do obviously is to remove the carb from the bike. Lots of bits can be removed to help in this so start with the fuel tank and the seat. I also like to remove the exhaust system. You can do it with it in place but it’s a pain. Another thing that makes it way easier when its out of the way is the rear shock and spring assembly, but unless you are doing a full strip down then leave it in place.
Before removing the carby, I like to release the drain screw on the bottom of the float bowl to remove the fuel (if any) that may be left in it. It will save you getting covered in fuel when you remove the carb from the bike and you can let it drain while you remove the other bits. Place something under the bike to catch the old fuel. Stale fuel stinks and the smell lingers and seriously does not agree with me.
First thing to remove is the choke cable and plunger. A 14mm open end spanner will help you with this. Then remove the throttle cable using a 10mm spanner to loosen off the adjusters in the bracket assembly.
Loosen off the two clamps holding the rubber manifolds on at the front and rear of the carb. Pull the carb to the rear to release it, the rear rubber manifold is a lot more flexible than the front so you can mash it up a bit to help get the unit free and out of the bike.
When removing the carb, take note of where the overflow hose is routed and its relationship with other wiring that lives near it, It may help you getting it back together neatly without kinking hoses and so forth. You might want to stuff a rag in the inlet manifold while doing this work too.
There we go, part one down and the carb is out and on the work bench. Keep an eye here to read about the meaty bit of stripping down the carb.