I have an '07 Foreman 500 with only 40 hrs on it. It's been in the shop twice already for clogged carb, said it had some bad gas. First time gas was removed and refilled. Halfway through the tank it wouldn't start. Took it back and carb clogged again. I had them put an inline fuel filter on it this time. I got 3/4 of the way through a tank and it started sputtering again and shut down. I checked the filter and there was nothing in it, but no gas either. Jostling around the fuel line, i can get fuel to flow again, and one time i got it to flow by switching to the reserve fuel, but it is happening often.

My thoughts are it has to be in the line or the filter in the tank. A diagram of the tank that i found shows a type of filter as part of the petcock assembly. Are these accesible without taking the entire tank off?

Any suggestions would be appreciated.

 

The empty fuel filter is what caught my eye. I have seen a clogged tank vent, confound a mechanic for endless hours while they investigated every other possibility. Be sure that isn't your problem, before you procede to other options.......

 

Wherever you bought gas, go elsewhere. Sounds like the fuel system needs a thorough cleaning. First start with the vent line, make sure its completly clear, also check where the free end is placed. On my 450 foreman it goes down by the handlebars. sometimes water builds up down there which blocks off the vent hose causing it to sputter & run out of fuel.

Next take off the tank, remove teh fuel switch and fitting to the tank and clean everythign thorougly. If stuff got in the carb and plugged it up, it went through all this as well, and is probably still there. Clean the tank itself thoroughly as well.

 

I would also say loosen the fuel cap and see if fuel flows. If so, either the vent hose is pinched, or the fuel cap is defective, not letting air into the tank to replace the volume of fuel consumed.

If that isn't it, then I would remove the tank. It isn't hard to do. Clean the screen, take apart the petcock assembly and inspect, and flush out the tank.

I'd also investigate where the contamination came from. You could have gas jugs with gunk in them, and/or a station delivering contaminated fuel.

 

Thanks for all the great advice. I'll check out everything mentioned and try and find the source also.

It looked like from the diagrams that the tank is bolted on by a flange on the front and th petcock by a bolt in the center of the dial. Does that sound right? Just trying to see what i'm about to get into.

Thanks,

 

I always recommend filling gas through a funnel with a strainer in it - 'cos very often gas straight from the pump is contaminated due to bad filters at the station itself. Also gas containers are often suspect.
A good strainer can save an engine rebuild , if fuel overflows the carb and gets into the engine oil -- which I see a couple times a year.
Also I don't like those inline fuel filters - they can lead to trouble - better to get the thing right from get go..
Clean fuel system and carb and you are good to go.
what guys say about vent is right also.

 

If I recall correctly, there are two bolts with rubber collar/insulators on the front of the tank, and on the back there are two rubber straps that clip onto hooks on either side.

There is a red two pin connector for the fuel gauge that you take apart, along with the fuel line. The petcock is held to the tank by two screws.

Naturally, the fuel tank cover has to come off first. Remove the seat, the starter cover and the left side cover, and the fuel cap. There are 9 of the little push clips, and a couple small bolts.

You then shove the cover forward to disengage little hooks from slits on the front fender.

It really isn't that big of a deal. Post back if you have any questions.


P.S. If you haven't had the break-in valve check done, it is due, and getting the tank off is half the job...