Howdy - my 02 400ex has a bit of a leakage issue. There is no flooding or fowling of plugs, but the bottom of the carb POURS fuel out. It doesn't do it all the time, but 85% of the time, I have a big ol' puddle of fuel under the machine after I beat on it for a while. I've built the carb 3-4 times over the past 2 years and it has not helped one little bit. I'be already installed a new petcock and that's the only way I can keep it from losing my fuel on the trails.

Thoughts?

 

You have a problem with the float needle or the float itself. Did you fit a new float needle during one of those rebuilds? If not, then get one and fit it. The most common problem is dirt from the tank jamming the needle open, so fit an in-line filter, however the paper ones will air lock if run dry, so try not to need reserve with a filter fitted, or place it so it never gets dry. Finally, if you get problems after that, you may have a faulty float or needle seat.

 

I don't remember specifically but I can pull it back apart to see.