From the way that you have described things I am beginning to think a loose wire. Ran fine then it didn't, you cleaned the carb and put dial-a-jet in and it ran fine then the next day it didn't. Spontanious and erratic.

This makes me think a loose or frayed wire, grounding intermitenly. Before dishing out more money I would start to trace some wires. Could be a loose battery connection, a loose ground etc. The battery could even be bad. Try disconnecting the battery while it is running. Replace the plug wire. Things like that....

 

Are you sure the choke lever is closing all the way? The enrichener circuit may still be on.

 

buckaroo, I think I've found out what's been wrong with it this whole time. I've got to do a few more controlled experiments though to prove it. I'll probably do them tomorrow afternoon and get it all back together. I'll probably post tomorrow night what the problem was.

I want to make sure before I post the 'solution'.

 

Well, I finally figured it out and the Ozark is running great. Dial a Jet works well. I can feel it pulling a lot harder in mid range to WOT then before. Thanks for everybody's help. [img]i/expressions/face-icon-small-happy.gif[/img]

I called the local Suzuki dealership this past Friday and spoke to the service manager about the problems I was having. He answered all my questions and helped me figure my problem out. I could tell he wanted to hurry the conversation up because I talked his ear off. In talking with him I asked him about something I had noticed the first day that I started trying to fix the Ozark, the vacuum line from the petcock was wet with fuel.He said (which I should have done it in the first place and I did think about it) to eliminate any tank or petcock problems to run a test tank and that the vacuum line should not have any fuel in it. I went to the local Advance Auto parts and got a overflow tank ('puke tank') for a couple bucks to use for a test tank. When I got home I plugged it up the carb and filled it with fuel. Ozark fired right of and idled perfect (after a little tuning). So, I took the petcock apart and found the problem. The diaphram had a good size hole in it and this allowed the vacuum via the line to pull fuel into the carb after the butterfly valve. Too bad one can't just purchase the diaphram (which is WAY to thin) instead of the whole petcock for $70[img]i/expressions/face-icon-small-frown.gif[/img]. So, I vacuum capped the vacuum nipple on the carb and petcock (effectively making it a manual petcock) and hooked up the tank back to the carb. [img]i/expressions/face-icon-small-confused.gif[/img] I might get a new petcock later on. Thanks!


So, the moral of the story is if you are having fuel problems with your Ozark check your petcock vacuum line first. PS if I get another petcock I'm going to put a clear fuel line on it!

 

Hey everyone!!!!!!

I found a cost effective solution to the vacuum petcock (when I was working on a friends atv)!!! A replacement vacuum petcock is currently $70.58 (and you can't just buy the diaphragm and the internals needed). An older manual style petcock for a Suzuki King Quad is the same price and you also can't buy the diaphragm and the internals. A Yamaha petcock is very inexpensive (was $13.90 when I bought it last week, currently $14.07) and you can purchase the internals!!!!

<span class="FTHighlightFont">Yamaha P/N is 21V-24500-11-00 </span ft>

If you can't find the it the petcock is for a 2002 Yamaha Wolverine.

I got mine from DGY Motorsports online (they are cheaper than Riva Motorsports).

The only thing that I had to change is a new fuel line (with a filter). Works great, I tried it today.

 

And it bolted up to your tank? I think your petcock attaches with 2 screws and has 2 tubes that goes into the tank?

 

Yes you are correct, one long tube with a nylon strainer filter (on setting) and also a short one (for reserve).

It bolted right up and saved some $$$.

 

Anyone have any input? I have an 03 ozark and when the petcock is set to the "on" position the quad seems to not want to idle and sputters when I give it gas. When I switch the petcock to reserve it seems to work fine/better. Does this sound like I need a new petcock? Do you think the stock fuel hose will hook up to the petcock for 02 yamaha wolverine?