Nope, still doing it. Let it idle for awhile, and sure enough, the fuel filter emptied out again. I know that the pedcock isn't the problem now. So where does that leave me? Something with the carb I guess. If I blow on that top vent hose gas is pushed up through the main jet, so I guess my next step is to pull the carb apart again and inspect everything. Could all this be a symtom of something sticking or just not working right?

So, is there anything left as far as the fuel delivery system goes? Is it strictly a gravity fed system? Or is there something else somewhere that contributes? I need some help, I'm about out of ideas.

 

usually there is some type of vent on top of the fuel tank for venting. for example what happens when you try to pour gas out of the container when the small vent opposite of the part where gas comes out is closed, gas dont come out. but when you open it gas flows. the vent in the fuel tank may be plugged. BUT i dont even know if it has a vent but i would think it has to. hope this helps

 

All tanks should have some sort of venting system. And that's what I think your problem is. Try letting the bike sit. Open the gas cap. Turn the fuel on. Start the bike and see how it behaves. I'm not sure on the xplorer, but does it have an on/off switch on the gas cap? If it has an internal venting system and it's not functioning properly (as determined by aforementioned test) then you should only have to replace the cap.

 

I THINK that I've tried removing the cap before, but I've done so much that I'm really not sure. I'll try it again. As far as what vent system it has, the cap does not have a vent. There is a right angled vent on the top of the tank under the plastic cover. And there is no on/off switch on the cap eitehr. The only switch is the pedcock (fuel valve).

 

ok so we know it's not the petcock now. I would try running a line straight from the carb to the fuel filter then from the fuel filter directly into the top of th tank. the only way we are going to track this down is to isolate each system. My other thought is with the fuel filter is it a pretty fat one like they use on cars or is it pretty small. If it's a big filter then when fuel leaves it it may not create enough pressure to fill it again. other thought was that maybe the filter is too small and it can't keep up with demand. everything that you are doind is leading us right back to that fuel filter. I think that's what we should focus on next. you said you replaced all the lines. did you but little zip ties at each plug in point for each fuel hose to prevent air leeks. air is much lighter and easier to draw into a system than gas is
Lemme know what size and brand of filter you are useing. you really want a straight in line filter without a resovor.

 

not sure about the brand of filter. I put it in and threw away the package. It is a fatter filter than the old one though. The old one had an outside diameter of a bit over 2 inches, the new one 4.5.

I went ahead and ran a line straight from the pedcock to the carb. I know that the pedcock is clear, so this should test the filter. Interestingly, when I detached the hose from the carb and drained it to a gas can, I forgot to shut off the pedcock. The gas ran strong until I shut off the valve, so it seems like the problem is whatever pulls down the gas.

The quad ran for 35 minutes then died. I'm assuming it ran out of gas again, even though the tank is 3/4's full and the in-tank screens are clear. So the problem is somewhere in the actual fuel delivery. Its just not pulling the fuel down fast enough or something. I just don't get it. What is used to pull the fuel into the carb? Is it strictly gravity feed, or is there something else like vacuum that helps?

Could it be something in the carb? Or could it possibly be the reed valves are sticking and aren't allowing enough vacuum to re-enter the carb and aid in pulling down fuel? I don't see what else it could be in the actual fuel line area. I really don't know much about the carb and lower part of these engines, so I am just guessing.

 

I'm running out of ideas hopefully somebody else has a few.

 

Scrama, I forgot to tell you, you are the man! Looks like the problem was a couple of things. One was that my fuel filter had too large of a reservior, and the second was that my tank vent was clogged. If you remember, I removed the filter and tried it and no luck. So in messing with it I decided to go ahead and try farmer boy and MeYHymNs idead, and it worked! Thanks for hanging with me on this scrama, this thing has been kicking my butt for months! Hope this helps someone else too!

 

Man that's great to hear. I'm so glad you got to the bottom of it.

 

Well ur post looks interesting as my 1999polaris 400 2 stroke coming home one day spudding with one backfire then died for month now I can’t figure this out best way to find problem is sounds like choke kills ((my pull start)) runs no battery pls help me ride again