Ok, let start with the beginning. Last weekend I rode my 01 Scrambler 500 for the first time in 3 months. We went to the cheese country trails in Wisconsin.

About 2 miles later, I smelled gas. The carb was overflowing, and the overflow tube was "peeing". I had a small screw, and plugged it up. Needless to say, I was running a bit richer, but hardly noticeable.

I replaced the needle and seat, and attempted to set the float height. However, my genuine Polaris manual shows a different carb float design then mine. I am still leaking!!!

1. Can anyone share their experience with this? It's a Mikuni BST 40. It has the factory jets and airbox. Never been touched until now.

2. I believe the float level is wrong now. The old needle had a groove, and leaked when I tested it. Now it's not peeing out, but dripping while riding. It doesn't drip while stopped at idle, so my thought is the float level is too high, and it's going over the overflow tube.

3. How does the throttle cable route? It makes no sense to go from the right side, under the fuel tank, and then back down the right to the throttle on the carb. I notice that my cable is tight, and when I turn a corner, it sometimes speeds up.


Thanks for any suggestions,

Rainman

 

bump

old thread, same problem

 

set the float lower