Xplorer 300 Overflow Tube

[frugalsob]

Hey all, been a while since my last post and can't find anything exactly like I'm experiencing. 

I have a 1996 Polaris Xplorer 300 and have fuel consistently (based on my opinion) drip from the overflow tube attached to the bottom of the carb. When parked and the fuel petcock turned on, it does not leak. However, once its running, it drips almost 1 drop per second. But only at idle. Once rpm's increase it doesn't drip. 

I've cleaned the carb, checked the float per service manual, and the rubber needle tip doesn't appear to be worn. 

Is this dripping normal? I really dont feel it should be. Or, do I need to replace the needle despite how I feel it looks. 

Any help would be appreciated! 

Thanks!

[Gwbarm]

Not normal, i would replace the needle and clean the seat good doesnt make sense why it only does it at idle unless its just using enough gas to keep the needle moving and not seating back correctly, when you are riding its using enough gas to not overflow and when stopped it seals once enough gas fills the bowl.

[frugalsob]

2 hours ago, Gwbarm said:

Not normal, i would replace the needle and clean the seat good doesnt make sense why it only does it at idle unless its just using enough gas to keep the needle moving and not seating back correctly, when you are riding its using enough gas to not overflow and when stopped it seals once enough gas fills the bowl.

That was my assumption as well but needed some confirmation. 

Dumb question, but air in the fuel line shouldn't cause or impact this, right?

[Gwbarm]

No it shouldnt , if any is there it will work its way out.

[frugalsob]

Thanks for the feedback and help!

I got a new needle and seat ordered last night and should be here for the weekend.  Fingers crossed.🤞

[frugalsob]

Well, new needle and seat came today. Got it installed and still experiencing fuel coming out of the overflow tube. 

I'm at a loss. 

[Gwbarm]

Did you check your float level. Sorry i was sure that was it. I will see if i can find a carb diagram and take a look i dont see polaris that often especially one that old.

[frugalsob]

I did check the float level and it did align with the specs.  

HOWEVER!

**Take note of the "air in the line" issue I mentioned prior.**

I continued to mess around be cause I was completely baffled and can't leave this unresolved.  A few months, I changed the fuel lines using tygon type fuel line with spring style hose clamp.  I noticed that with that combo, it didn't take much pushing or pulling to create a leak at the fuel inlet.  I figured I would replace the tubing with the typical black re-inforced fuel/oil line with screw type hose clamps to see if that would improve the leaking and robustness of the system.  It did and I had no further leaking at any of the fuel line joints.  I reset everything again and tried a test run.  At first I was getting some fuel to drip out of the overflow tube, but because the vent tubing was still the transparent tygon tubing, I saw what looked to be air bubbles in the overflow tube.  Figured that was air purging out of they system.  Then the drips stopped!  I let the machine cool down, restarted and tested again and no drips.

I conclusion I can only figure is that with the tygon lines, it was allowing air into the tubing.  And because I could never get the air out of the lines, it would allow for the dripping.  Only thing I can figure.

I'm still going to monitor and see how things go, but for now, I'm going to call it fixed!  🤞

[Gwbarm]

That is strange usually you see a little wetness from gas in the area it might be sucking air. Thanks for the update hopefully thats it.

[frugalsob]

I did see wetness at the fuel inlet on the carb. It wasn't much, but that's what provoked me to change the fuel lines to the reinforced black tubing.