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Dra O

1999 suzuki king quad fuel pump/petcock/carb advice

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posted a while back - it was running at one point - I have all the plastic shroud off - it's down to frame and engine now
-fuel pump: when line from petcock is attached, no fuel comes out other side to carb; the line to the carb is open (can blow through it); I thought when I cranked engine that the pump would spit out fuel on other side but it does not; I removed fuel pump and opened it up - diaphragm looks good - but internal areas had lotsa calcification build up - I cleaned this out and dried it good - the clear plastic pieces (?diaphragms) aren't broken - the spring w/ steel ball on end moves freely; am putting it back on tomorrow; but can anyone answer about the pump? isn't it supposed to pump fuel through it... to other side... to carb? puzzling
-along with fuel pump: I replaced petcock 3 weeks ago (gas tank had rusty fuel in bottom - cleaned it out prior to new petcock); when I turn petcock arrow NOT to on or reserve, fuel comes out of line; when I turn it to on or reserve, fuel doesn't come out; puzzling
-I don't know what's on back of fuel pump - it's a valve that has a hose coming out of it - looks like it goes to engine/carb - I haven't traced this out yet - what is it?
-can squirt gas on air filter and engine will run for 2-3 seconds then stop - fuel in top of carb (under diaphragm) does same
-it likely needs carb rebuild - will get to this - but something isn't allowing fuel to get from fuel pump to carb

-I THINK it has a mikuni model x carb - diaphragm is ID 26mm  OD 68mm - hard to find inexpensive diaphragm, I guess because it's a model x

-last thing - I replaced solenoid due to old one clicking; I HAVE to be charging the battery or it won't start/turn over - battery just goes dead; but if charging, it'll turn over nicely; i'm guessing it's a bad battery
-any help appreciated - I've never owned an ATV before - inherited this beast from grandparent in-law

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The three ports on the carb are as follows: one port on the side  should be marked IN that should clearly be marked.  The other one on the opposite side will not be marked. That’s the one that goes to the carburetor fuel inlet.   The third one on the back of the pump is the vacuum line that activates the pump. That line also goes to the carburetor. It’s on the opposite side of the fuel connection on the carburetor.  What happens is when you crank the engine the vacuum created in the carburetor moves the diaphragm in the pump.  The vacuum that’s created is a pulsing vacuum it sucks in and the internal spring pushed it back out when there’s a break in the vacuum pulse.  If that vacuum line going to the carburetor is cracked or has a leak it’s not going to pump. If the carburetor is dirty and that internal port for the vacuum line  is blocked it’s not going to work.   So if you have any doubts about the carburetor being cleaned then get after it  and take it apart.  I posted a topic on carburetor cleaning, take a peek at it I’m sure  it will help you along if you can’t find the post let me know. 

Make sure your pump is not installed upside down and the lines are reversed.  

Lastly is sometimes the pump has to be primed. Connect up the fuel pump to the petcock but not to the carburetor.  Put a clean long hose on the pump and lightly suck in on that hose a few times and see if you get fuel out of the outlet hose that goes to the carburetor. 

As far as the petcock goes there is a plate on the inside that directs the fuel so make sure that’s installed correctly if you took it apart  or just put a new one in right out of the box.   

Battery could have a dead dead cell and won’t hold a charge. Replace it especially if you get this fuel line thing corrected you don't want  to go into the winter with a bad battery. 

Hope this helps. Good luck. 

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@Dra O maybe a silly question and I really don't know the answer but when looking at the parts diagram, I noticed two version of the fuel petcock for your YMM atv. Did you buy the correct one?

image.png.80fdfc4fa7d9284faf141f89dd7abd13.png

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I thought a petcock was a petcock (for a king quad 300).  I got it on ebay for about 10 clams.  it is different from original - the anchor holes line up on the tank perfectly but the diaphragm on the new on is slightly smaller than the original - and the rubber gasket on new petcock is just a hair too large for the original petcock, so much so that i'd have to splice it, defeating the purpose of the gasket and risking a leak.

I put original petcock back on today and it was leaking at the switch side (the on, prime, reserve side) - it seats well at against gas tank but the diaphragm, being 20 years old, is flat. i didn't want to spend 100 clams on new, crazy-expensive petcock to fit my specific machine but I may have to (120 on amazon and ebay - can't return it if used - lovely).

I watched a youtube video of a guy "fixing" a petcock on his Harley (similar carbs, apparently) - he elongated internal spring AND warped the inner metal piece even more (to increase tension/pressure behind the switch side) but this didn't work to remedy the issue.

this is getting frustrating, especially having a funky model x mukini and not the y version - there are plenty of parts for the y version.

might oughta consider selling the beast as is - it didn't cost me anything.  or take it to a shop and spend a few hundred clams - I don't know if it's even worth that much.

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Frank, thanks for the info - I will try to prime the new petcock this weekend with a hose - that sounds like a good idea - will use the existing hose that goes to carb. 

*** but shouldn't the fuel pump be spitting out gas to the other side when I crank the engine?  it isn't doing this....

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It would pump if it has vacuum from the carb. So take the line going to the carburetor and pull it off and crank the engine. See if it pumps.  You can also blow into the hose on the top of the gas cap while your cranking the engine to help it along. But if the carburetor is clogged and vacuum is not being produced then it’s not going to work.  

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i think i bought the same petcock from ebay. i took it apart because i figured someone put it together improperly. the one i bought was made improperly. the reserve position CANNOT function because it is not made right. prime and on work fine. but when you are out of gas, your walking. i rebuilt the original. more expensive, but i will not have to walk.

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