Help. I have been trying and trying to get my rebuilt express 400 to run . I discovered today that the main fuel line,from petcock to filter to carb was bad weatercracked . I replaceced it with 1/4 id fuel line and replaced filter with stuff i got from local hardware store. Now i notice im not geting fuel flow back to carb. there is barly any flow and fuel filter stays half full off air. What do i do? I tried to check the petcock vaulve. It feels somewhat restricted when i flow air through it with my mouth. But im not sure. any ideas. Do i just need to stop being cheap and buy replacement fuel line, filter and screen fittings for my fuel tank from polaris? The screen fitings were both clogged up. I cleaned them but still have poor fuel flow.

thanks

 

is the filter a 1 way direction filter and it's on backwards? was the line the same size diameter that you replaced? is the fuel pump working correctly(if there is one) and vacuum hooked up? just a couple of thoughts. is there a prime side on the petcock where the fuel flowing fuel can just run out or just on and on?

 

loosen the gas cap and see if you get any better flow. Just thinking that maybe the vent/ return line may be stopped up.

 

very good point that i forgot tp mention.

 

yes i had fuel fillter on correct dirrection with arrow pointing towards carb. There is a place for a vent line on fuel tank . i have a vent line on it that goes up into handlebar tree area. Is this the correct vent line? the carb has a float vent running down to bottom of frame. carb also has side vent line running into frame beside tank but stops there. I havent tried it with thw fuel cap off yet but will, to see if that helps.

I put another fuel line on directly from center fuel petcock dirrect to carb, with no fuel filter. i tryied this & got bike running with only about 1/2 to 3/4 throttle rev then i let it idlle down and it died. I still feel it isnt getting enough fuel.. What does the soilinoid on the thumb throttle do? I noticed the otherday if i pushed it in while giving it the gas i could get more rpms out of it.

I still think maybe the petcock is blocked or maybee the two wire screen fittings are partialy blocked as the exit fuel tank. Im not sure. I will try again once i get batery charged back up. I ran it down this afternoon trying to start and restart the atv.


Thanks for all the help.

 

oh the fuel petcock has three fuel lines. One goes to 90 fitting in fuel tank reg gas on/ having long screen inside tank The next goes to 90 fitting on bottom of fuel tank reserve /having short screen inside tank. the centerone goes to fuel filter then carb. I dint see any prime on it. It just has on ,off,and reserve on.

 

a way to check for sure if its the tank or line issue is to run your main gas line from say a bottle hooked to it (something to hold the gas to feed the engine)and if it runs fine then it might be a lack of fuel issue. don't know about any solenoid onthe handle bar unless you mean the etc which is designed to prevent the bike form going over so many rpm's if the throttle was to stick. there should be like 1/8" slack in the cable to be set right on the throttle onthe handle bars.

 

Did you clean all the jets in the carb? everything that was in the tank is in the carb, rust, bad gas , ect.

 

IIRC there is also a filter in the carb as well next to the pulse pump.

 

Update today.

I tried removing fuel cap while running, this made no difrence.

I did get it started but it seemed boged down then giving it full gas engine speed came up . i held it open for a brief time but then let it idle down then it boged down and died. didnt get it started again past low boging low rpm.

Now im thinking electrical problem again.

Next i unbolted coil. Its bolts were badly rusted AND THE post and wires rusted on it. Is it possible this being rusted is causing problems? Maybe bad grounding due to rust. The bolts holding it on both had the nuts snap of when i removed coil. I sanded rust of but didnt have new bolts to put it back on to try coil after i cleaned it.

also onece the atv dies it will not start again.

also i noticed the neutral green light is of sometimes and other times not. isthere a neautral switch somewhere i need to replace that may cause starting problems?

I drained fuel tank after i couldnt get it to start again to check fuel flow. It looked good so now i dont think fuel flow is the problem.


I also wonder about the etc solinoid switch in thumb throttle. maybe causing problems?