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.

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! 🤞

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.

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.🤞

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?

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!

I owe you Mech! Your explanation of the wiring diagram brought me right to the solution. The black lead off the kill switch was not tied to the black lead of the key switch. There were plenty of open spots on the terminal block the black key switch lead was connected to. I connected the black kill switch lead to the same terminal and it works like a champ! Thanks again! So VERY appreciated.

One more question as I plan to trace these wires: is there something I could use to spray down that area to clean it? Other then my air compressor. I was thinking mass air flow sensor cleaner?

Gotcha. Your last comment resonated with me and I think I'm following you. I printed off that diagram today while at work so I can try to follow it better. I'll check it out tonight after work. Thanks again for the help so far! It's greatly appreciated. I'll report back tonight on what I find out!

By on the board I meant I clipped a jumper from where brown and black respectively connect. In the first image the red test prob is where brown connects to the board and the black is where black connects to the board. The second image shows how I jumped the balck and brown on the board. Does that help explain?

Thanks for the replies guys! So I tested again and have continuity through the switch on blk/brn and r-w/r-blk. I also tried to jump blk/brn on the board as it was running assuming it would kill it, but did not. Is it possible it could be the CDI not grounding the stator?

Good morning all, I'm hoping someone can help out and lead me in the right direction. I tried a search and really didn't find anything exactly like my issue. Symptoms: Turn key on, neutral light off, turn kill switch on, neutral light turns on, starts and runs normal. While running, neutral light still on, turn off kill switch, neutral light turns off, atv continues to run and drive. Only way to turn it off is with the key. I tested the switch and wiring to the board and all of that checks out okay. My gut says it's possible a bad ground somewhere, but if it was, why would it start? So I'm kinda stumped for now, hoping someone here has experienced something like this before or knows what I should look at next...

I'm not positive, but I think the state's intention was to prevent riders going 2up on a single up seat. Unfortunately that's not how it worked out. I know a lot of people where we ride are pretty upset by it.

I use CRC or Permatex dielectric grease. And like the others have said, any electrical component that gets wet.

That's some outstanding country!