were riden today and i need to get mine fixed
my problem is it leaks gas bad on the overflow hose under the carb it leaked out 1 gallon in bout 10 min.
i tightened the bolt up and it didnt help!!
im stumped
later

 

Easy yet difficult fix. Mine did the EXACT same thing. Does it leak up above the fuel switch or below the switch?

The gas tank is made of injected plastic (what isn't on these bikes!?) anyhow, the molding line (or where the plastic meets itself or seams together in the injection press) cracked open. Unfortunetely you must take off damn near all the plastic (fenders, etc.) to get to the tank.

Once that is done, remove the tank (try to keep the tank as empty as possible) remove the fuel switch (two screws or bolts).

Now then, you can either spend about $180 for a new tank at the dealership or go to your local automotive store and buy some gas tank putty / sealer. It usually comes in two sticks that you knead together like dough. You only need a small amount. Use a screw driver or something of the sort to pry the tank apart where it's split, and wedge the putty in between. DO NOT apply the putty like a patch (over the crack). You must try to get the putty in between the crack(s).

Follow the directions on the putty regarding setup or dry time. Afterward, throw the switch back in, also a bit of gas, and test to see if it still leaks.

Another problem you may have, is the screws that hold the switch into the tank may be stripped. You can use the above mentioned putty to put around the stud of the switch that fits into the tank. Creating a gasket between the tank and switch. I only suggest to use gas tank repair putty NOT silicone or permitex, they won't hold up to gasoline.

That should fix your problem. If you decide this is too much work, try and find a local atv salvage shop. Not sure where you are from, but a place near me will ship you stuff UPS, it's called EMC Cycle in Yale, Michigan. You can probably call information for their number, I don't have it off hand. BTW, the area code is 810.

Take care!

Green is Mean!
'87 Mojave
'87 Tecate
'00 DS650 [bigger is better]

 

They way it sounds the gas float in the bowl is stuck in the down position and always calling for gas. Therefore the carb bowl is overflowing and coming out of the overflow hose on the side onf the carb. Remove the carb and take the bowl off and check the floats. This could be your problem

 

ok what does the floats look like?
i know what the jets are though
later

 

Do you shut off your gas?

 

i can shoot off gas
and it still comes out.i want to fix it and sell it
but im not going to screw nobody and sell it to them like that ya know
later

 

what do the floats look like?
i have the bowl off!
later

 

i put a new float vlve in it was 30 bucks
it didnt help a bit
how can i check the floats?
later