I have a 2000 warrior and haven't run it in approx. 5 weeks. Today I went to start it up and as soon as I turn the gas on, gas goes pouring out of the overflow tubes on the carb. I tried heating up the carbs with a blowdryer, but still had no luck.

I am able to start the quad when the gas is off (apparently just enough gas gets through the line to allow it to idle), but as soon as I turn the gas on, the engine sputters then dies, and gas goes pouring out of the carb.

Does anyone know what the problem may be and how to fix it!?

Thanks

 

A carb has a needle, seat and float that regulates the amount of fuel that enters it. In your case there is some dirt that keeps the needle from shutting the fuel off. You need to take the bowl off and clean the needle and seat.
You can get pictures off the net if you still don't understand.

 

tap on the side of the carb .float is hung.

 

As stated in the post from Dr.Turbo the needle valve is not seating correctly. I just had this same problem with my 05 Wolverine. I tried tapping on the carb and that didn't do it. What I ended up doing was removing the carb and cleaning the whole assembly. It's not that big of a job and I will take you through the steps I took. I believe your Warrior is set up very similar to my Wolverine.

1 - Shut off the fuel at the petcock.
2 - Remove the fuel line from the carb (2 spring hose clamps)
3 - Pull the 4 screws and remove the throttle linkage cover (black plastic cover to the right of the choke)
4 - Remove the cable from the throttle assembly (use your finger to rotate the throttle an pull the cable stop out from throttle assembly) Remove the cable stop.
5 - Loosen the throttle cable adjusting tube on the top of the carb and pull the cable out through the tube.
6 - Loosen the screw on the rubber intake clamp and do the same manifold clamp.
7 - Remove the overflow tube on the bottom of the float and the breather tube from the side of the carb.
8 - With the seat off the machine you can pull the intake boot back enough to free up that side of the carb. once that is free it makes it easier to pull the carb back enough to remove it from the manifold. At this point you should be holding the carb in your hand.
I recommend doing the rest of the job on a bench where you can have somewhere clean to assure nothing gets dirty or lost.
9 - Remove the 4 screws from the float bowl and pull the cover off. You will see the float and needle assembly.
10 - The float can be removed by pulling the pin out (it only comes out and goes in one way.
11 - Once the pin is removed you should be able to remove the float and needle as a unit attached by the little clip.
12 - After the needle is removed from it's seat you can use some spray carb cleaner to clean the whole assembly. Make sure you spray a little through the needle seat to clean any dirt or varnish that may have collected.
13 - Inspect the rubber on the bottom of the needle (if it show any wear replace it)
You are going to want to adjust the float after you assemble that part of it.
Google float adjustment to get that information because I know how I do it,but there are a couple of ways to do it and you should follow the instructions from them.
Once you fell that you have cleaned the whole assembly than reassemble everything in the reverse of the way you removed it.
Good luck and if you have any questions let me know
I know that this worked for me and I haven't had a problem since.

 

Either a bad seat on the needle or the stuck float are both good ideas for this problem. Obviously I would go ahead and try the tapping on the side to check on the float test, and if that doesn't alleviate your problems then follow lightningz excellent directions on cleaning the needle and seat.

 

Thanks for the help so far, especially the instructions... Right now I'm at the point where the carb is out. However, I noticed something I dont particularly like.

The tube that goes down into the engine (that is connected to the carb) has black sooty stuff lining the tube into the engine... The seals on the carb to the engine are good, and the carb has none of this sooty stuff in it.

Does anyone know what this is / is it normal / is there anything I should do about it?

 

Thats just carbon buildup in the head. A side effect of any internal combustion engine. A good polish job is about all you can do, but it isn't hurting your engine to be like that.

 

Update:

Alright, I cleaned out the carbs (even though the bowl and floats were spotless with no gunk what-so-ever), and the floats were moving perfectly with absolutely no binding.

After cleaning I put everything back together and for the first 30 seconds or so, no gas leaked from the carbs but then it all happened again.

WHAT I DIDNT DO was take out the pin that holds the floats on, because it was stuck like hell and no matter how much pounding, it would not slide out (any tips on removing it!?). I know I should have just kept the carb out of the machine until I could get the needle out but I was impatient and it all looked clean.

In the next couple days I will take it all apart again, so does anyone have any tips on getting that pin out; On my CR125 the pin easily slides out but this one seems to be locked in there (and yes, I'm sliding it the right way).

Are there any other things I should do!? I really don't have the $200 that my dealership wants to do this job

 

 

you need to have the carb rebuilt and put in new floats and needles