Converted to the manual petcock after having so many issues with the vacuum style. Quad was apart for awhile, and I'm figuring when converting you need to plug the old vacuum line on carb. So I removed all the hoses and not sure which was vacuum, so I figured just to feel for vacuum when running. So I plug the rear hole, no effect, when I plug the front one the quad just dies. Am I plugging a vent by accident ? I figure if I plug the vacuum I should just have to raise the idle, but it dies right out after a few seconds and doesn't really feel like there is vacuum there. Has anyone done the swap, and plugged it ? Should I leave it open or will it run too lean ? Runs fine without plugging except idles a little high.

 

Hole closest to the motor is the vacuum. Front hole is the vent.

 

So the hole closest to front is vent , should it die when I plug it ? Also just did a top end rebuild, head gasket is leaking after a few hours riding, any ideas ? Does the gasket need sealer ?

 

The vent hose runs up under the hood. It should run being connected.
Prolly need to re-torque the head bolts. What torque did you tighten to? No sealer needed.

 

I'm a little confused now, because I just found a pic in my manual saying the opposite, closest to front is vacuum and rear hole closest to motor is vent ? But, just curious if I plugged the vent or vacuum, should it cause it to stall ? And since I swapped out the petcock to a gravity feed, should I block off the vacuum line that used to go from carb to petcock ?

 

Looking at the carb from the right side: left hole is vac. Brass tube is fuel inlet. Right hole is the vent.
I guarantee you that the hole closest to the motor is the vac. And yes, plug/cover that.
Is the vent tube clear? It should run with the vent hose on.
Torque on head nuts?

 

Now I looked at instructions for a gravity flow petcock and it shows a pic showing to plug the left, rearmost hole, so my manual is wrong. I torqued to 100 inch pounds, new studs, maybe they stretched with the heat ? Can I re-use the head gasket ?

 

Yes, you can re-use the head gasket.
Maybe go a lil tighter. 115-120 inch pounds. OPT says the polaris mini requires 150 inch pounds. I'm scared to go that high but they say they have no problems.

 

Thanks for your help LT 80.