Alright guys, I am to my breaking point with this problem. I rebuilt my 91 kq 300 about a year ago. Since then it has had a ton of power and ive been really happy with it. Then two months ago i went out of town for a while and the machine didnt run for a long time. Now every time i go tp start it, it cranks a few times, then the starter binds. And i mean binds really hard, to the point of not being able to turn. I thought it might be the valves since every once in a while it backfires through the carb when starting it. But today i pulled the air filter and saw that the carb was almost over running fuel into the air filter. I have no idea what to do with it and the thing is becoming a colossal money pit so if anyone can help that would be great.

 

Not familiar with the 91 KQ but most Suzukis have a fuel tap worked by the inlet vacuum, if you leave it on prime or the tap starts to leak, fuel is stopped from leaking into the engine and air box by the float needle. So if this also starts to leak, the cylinder and air box fills with fuel. Check the tap, fit a new float needle, empty the air box and change the oil. It will be hard to start first time afterwards with all that excess fuel making the mixture very rich.

 

After all that, run non ethanol fuel.
Many float problems from ethanol.

 

Ok, Ill look into getting a carb kit and doing that. Thankfully my machine was made before that horrid vacuum valve