Ok, fixed some other stuff to get my 95 Xplorer 400 to stop mysteriously stalling, and in the process I replaced the fuel filter with a new clear one. It was a bit longer than the old one, so I got some new fuel hose and relocated it to just below the pedcock (or however its spelled). Everything seemed to working finally, and then after about 20 minutes it stalled again. I checked, and there was no fuel at all flowing down into the fuel filter. Doesn't matter if its on main or reserve tank, no fuel would flow. After about ten minutes it finally started a slow trickle, enough for me to go and park it, but not nearly the normal flow amount. Once it sat for a while the filter filled back up with gas, but I'm thinking that this has been my problem all along. What could be causing this? I can see two seperate hoses for the main and reserve tank, so is my pedcock sticking or is there something else. Could it be something with the carberator? It seems like if I disconnect the fuel hose from the carb the gas runs ok, but who knows? I have noticed that there is a tube coming out of the float bowl at the bottom of the carb that has what looks like a vacuum switch on it, but the vac switch isn't connected to anything. Is that normal? Thanks for the help.

 

I think you might be on to something now. That little thing at the end of the vent hose should be a vent line filter. The carb needs to be able to breath in and out as the float bowl is filled and emptied. That little suction can cause crud to be sucked into the carb. That is why there is a filter. That filter may be plugged, not letting the bowl fill. Take it off for a bit, run it around and see if it helps. If so, get another one and have fun.

 

I'm trying that right now, but I noticed before when I was messing with it that it only works in one direction. It lets air/fuel out, but not in. Is that normal?

 

Ok, after trying out your suggestion and watching, I can better describe what is happening. I first tried it with the thing on the bottom vent hose. It ran fine, although the fuel flow into the filter was less than the output. So once it drained the fuel from the filter it stalled. I removed the filter or whatever it is off the bottom vent hose, and nothing happened. I tried opeing the fuel cap (test the tank vent) and nothing happened. I tried switching between the main and reserve tank, and nothing happened. By saying nothing happened, I mean that no fuel came into the filter. So out of curiosity, I blew into the vent hose that plugs into the the top of the carb, and suddenly fuel came flowing into the fuel filter. I cranked it and it started right up. I noticed that the fuel input was still slower than the output though. I tried blowing on the same vent and that stalled it. So where does that leave me? Any suggestions anyone?

I just had a thought. Could this be caused by a bad air filter? When I bought the quad (about a month ago), the previous owner had taken it to a polaris dealer and had a bunch of maintence done on it, including a new filter. It looks fine, but maybe there is a problem with it.

 

Could the needle or float be sticking in the float bowl? When it's running slow try tapping on the bowl. Also could just need some soaking in a carb cleaning solution.

 

I've cleaned the carb several times, and when I've had it pulled apart the float and everything seems to be plenty free. I'll try it again though. I think that I'll try replacing the air filter too. I still am not sure how or what that breather tube at the top of the carb does.