My sons 2003 Sportsman 90 keeps leaking gas right under the air cleaner. I disconnected the hose from the fuel shut off valve and gas kept running out even in the off position. I took apart the fuel shutoff valve and found the rubber seal inside had a chunk missing so I replaced the whole shut-off assembly. Well I went out to the garage this morning and there is a puddle of gas under the quad again. I've checked the obvious like hose leaks but found no problems.

Any idea what I should be looking for? Maybe a float problem?

 

From what I understand you could not see an active leak that produced the puddle after the valve repair. Could it be that residual leakage from the prior leak had gathered on the chassis and or elsewhere then dripped down and made the puddle? A stuck float would generally pour fuel into the motor possibly out the carb vent but only a little unless it was being supplied by the pump--running.

 

If the carb vent line is clogged or plugged gas could make it's way into the airbox....I think....I had this happen on a 4-stroke witha bad petcock and a clogged carb vent hose and a stuck float.....[img]i/expressions/face-icon-small-smile.gif[/img]

 

I took the air cleaner box off and found the gas is dripping out the tube on the bottom of the bowl. I beleive this is an overflow vent so does this mean I have a problem with the float?

I did figure out the shut off valve problem- I had the hoses incorrectly connected.

 

If it is the long tube directly below the float bowl, attached to the screwin plug that exposes the main jet and has a plug in the end that is not a vent tube. It is a drain tube for water and debris in the fuel without taking off the bowl and should not be leaking. It has nothing to do with float level. Repair or replace it. All the vent tubes I have ever seen are located above the bowl on the main body and are far smaller in diameter

 

It was dripping out of the overflow tube on the bottom of the bowl- this is not a vent but an actually overflow drain for the bowl.

I took the bowl cover off and sprayed everything with carb cleaner and inspected the float and needle operation.

Everything looked good so I put it back together and it is not leaking anymore- must be something was causing the float to stick.