Jump to content

  • Join Today, It's Simple and FREE!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.


1998 Kawasaki Bayou 300 carb leaks

Recommended Posts


Have had the carb apart twice now and can"t find any obvious problems. but if I leave the fuel on it floods the float bowl and leaks out the overflow. What should I be checking?

Share this post

Link to post
Share on other sites

hey let me start by giving you some background on my problem. i have a 97 bayou 300 4x4 that i am having the same problem with. atv runs perfect, but fuel running out of the overflow hose even with the petcock off. i took off fuel line from petcock and petcock will not shut off. i jacked with petcock for a minute and opted to order a new one. i bought a new petcock from bikebandit.com and replaced it. it cost me about 80 bucks...ridiculous. now my gas will shut off to carb i have had my carb apart at least twice trying to fix the overflow problem. Today i took entire carb apart and inspected needle valve and decided to order a new one...i am almost certain this will fix my problem. it has been very frustrating...i have done extensive research looking for the solution to my problem, which seems to be identical to yours. This is what i've found.

#1 check the drain screw on you carb located directly above the drain/overflow hose. i would suggest backing the screw all the way out and letting a decent amount of gas come out. catch it with some paper towels and pay attention if any trash comes out. There could be a piece of debris not fully allowing the drain screw to fully close. This is probably not your problem as it was not mine. I also replaced the screw since the allen head on my was almost stripped?! It wasnt because of me...previous owner i guess.

#2 You could have a leaking float...it could have a minute hole in it causing it to fill up with gas...This is also probably not your problem as it also was not mine.

#3 float height is not set correctly. I don't believe this is either of our problem since there I am almost certain there is no adjustment on these machines.

#4 Your needle valve and or seat is worn. I am almost certain this is both of our problems. I ordered a new valve from bikebandit.com...didn't shop around...probably should have. It cost 30 bucks...also ridiculous...i heard some people talking about getting aftermarket kits for around 15 bucks...but i personally prefer OEM. I just want this nightmare to be over and i'm tired of jacking with it.

This is the next step i would take if i were you. bite the bullet, order a new one, and change it out. The seat is pressed into the carb and i wouldn't have the slightest idea how to change it out. I wouldn't worry about this too much though because it is probably the rubber on the needle valve that is worn. I did hear some guy talking about using a wooden dowel to polish a seat but i personally am banking on the new needle valve fixing our problem. here is the link to the dowel procedure as well as more background on this specific problem...Reading This May Solve Your Leaking Carburetor Float Needle Valve And Seat Problems - Kawasaki Motorcycle Forums

I hope this helps

Share this post

Link to post
Share on other sites

Did you get a rebuild kit? Sounds like the fuel flow is not shutting off when the float is at full level.

Share this post

Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Nick Brooks
      Working on a 2002 Quest 500 and the grommets in the tank are rock hard and leak.  Any tips on replacing without having to pull the tank, hands are too big to get to the bottom gromment which is the worst one.
    • By MarkinAR
      What is the opinion on carb kits? What's one of the better brands of aftermarket? OEM is always preferred but not practical, chinese cheapie is never a good option. 
      Thoughts ?
    • By Ted Aregi
      I've got a king quad 750cc has anyone converted the fuel pump relay to a stronger fuel pump relay on there king quad?
    • By josephnbl91
      My four wheeler when i first got it seemed like it was very slow when i first got it and it had no throttle response so i replaced the belt and cleaned all of the rollers thinking that would solve the problem from what i read on the forums. well it turned out that it wasnt. so i went to the next thing i took out the injector to check it out and i seen that there was a tiny bit of debree in it so i cleaned it and it seemed to improve a little bit. but still did not solve the problem. i later found out how to find the trouble codes out from the lcd screen using a paper clip on the diagnostic port and it showed the code which stood for no codes C00. i also forgot to mention that the throttle position censor is working perfect. before i started all of this the four wheeler ran just not to its potential. after my friend and i did the trouble code test the bike wouldnt even start anymore and the injector would spray for a few seconds for the start up then it stops and the fuel injection light comes on and blinks. the four wheeler wouldnt start anymore. i took it over to the local shop and they hooked it up to the computer to see if there was any codes and it still showed it was free of codes. they hooked it up to the fuel pressure gauge and we found that it was making 22 pounds and it should be making around 43. i then bought a new fuel pump and put it in. it now starts and runs for a few seconds and then it stalls out and the fuel injection light comes on again. which then leads me to think it is the ecu now but i want to be sure before i invest around $500 more into it. any opinions on whether or not anyone thinks this is the problem or if they have had a similar problem before would be really appreciated. sorry for writing a novel and not spelling very well. also i forgot to put the year in the title it is a 2007
    • By Christopher Freshwater
      I just got a 750 brute force was not running been working on it all day finally got it running but rear cylinder acts like it cuts out and then starts working again and the fan does not come on
  • Similar Tagged Content

    • By weblex
      Problem: The ATV starts and runs at idle perfectly. But as soon as I open the throttle, the engine starts to slow down until it stops. On the attached video you can hear the sound of how it works: see video below
      Prehistory: there is a Polaris Sportsman 500 1998, which for about 1.5 years stood in repair, including also replacing CDI with one taken from the same ATV. Finally, the vehicles were on wheels, traveled several kilometers and overheated - forgot to fill the antifreeze Came back home in small moves. The next trip started well, but after 10 km there was a feeling of a small drop in power (even as the vehicle got warm completely) but still drives. Next trip - the situation is repeated. The next test of ATV through time and a huge loss of power from the very beginning. The engine sneezes, does not want to go more than 5 mph.

      What has been done: the carburetor has been replaced with a new one (inexpensive, $ 40), a new spark plug, a new ignition coil, the engine head has been removed, the piston is in good condition, valves were corrected - but the problem was definitely not in them.

      Ignition control unit is suspected. Who faced similar? Please help in solving the problem.
      Thanks in advance.
    • By brad1
      I have a 2003 Bayou 250. Suddenly, it won't start with the start switch. No clicking, no neutral light on. It will pull start fine. The battery is new. Any idea what to look at first? Thanks.
    • By ut1w7b
      I have a 94 sportsman 400. It sat for several years before i got it. I have cleaned the carb it will start and run for about 5 min then it will flood. I have torn it down and cant see anything wrong. has anyone else ran into this problem any hel would be great.
    • By ej200421
      i was wondering if i could get some help. i been trying to locate where the fuel and air adjustment screws are located on my 95 kodiak 400. i think i found the fuel screw.. i know where the throttle adjuster is but i cant find the air screw. or is there an air adjustment on these carbs?
    • By Wonderwoman
      Hello, well back to where I was last year with this carb. Took my 250 to the mountains for the first time this year and blue smoke, too much gas again. I can't believe that this carb gives me this much trouble. Seems like the choke is stuck but the cable moves freely. Anyone else ever experience this issue? Do you think a new choke cable would maybe resolve this?http://www.quadcrazy.com/atvforum/images/smilies/arghh.gif
      OK it was the choke. Put on all new cable and plunger and she is running 100% again. So now the question is, is the carb getting worn out where the plunger needle goes in the small hole and when I use the choke the needle end doesn't get lined back up with the hole?? We'll see how it runs and now that I know what the issue is I can always pull the choke plunger out and reinstall if I start having this issue again.
  • Recently Browsing   0 members

    No registered users viewing this page.

  • Create New...