Ongoing project, 300 fourtrax. - Honda ATV Forum
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post #1 of 620 (permalink) Old 09-24-2017, 11:55 AM Thread Starter
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Ongoing project, 300 fourtrax.

Figured I needed this thread rather than asking questions relating to 'my' 300 in others threads.

As those of you who follow my madness will know, I've recently refitted my snorkel, to which I tested out at the off-road park today, works a treat, everything appeared to be watertight too, submerged above the bars for quite some time in a small lake!
The issue I encountered after snorkelling was my carb was leaking fuel out of the bottom overflow. I fitted a brand new OEM needle valve and thoroughly cleaned the carb, this did the trick, happy days.
This morning I fired it up and loaded onto the trailer only to find it was leaking out thenoverflow again. Annoying on the morning of your planned days ride!
I removed the carb, cleaned and refitted.... 3 TIMES!
Got to the off-road park, yep.... It was leaking again!

I decided to ride anyway as the leak seems to stop after quarter throttle, even at the end of my days riding it still leaked when I pulled up at the trailer. Loaded up, got home, jet washed the 300.... No leak!!

I'm completely stumped, I can't tell you how clean my carb is, its pristine inside, I mean surgically clean!

As for the needle valve, I have cleaned the seat with toothpaste and a cotton bud, before this I used 1200 grit wet & dry with WD40 rolled up into a taper.

What do you guys think?

I'm thinking I've knackered the seat with the wet and dry or try a new float and see if that does the trick. Could be slightly misshapen maybe?

98 300 Fourtrax 4x4

Custom built mud bike - Now sold.

2004 Foreman 450S

Fully overhauled (nut & bolt rebuild), 2” lift kit, 28” mega mayhems, ITP delta rims, ES floorboards, 22” LED lightbar, Pyle Bluetooth sound system.
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post #2 of 620 (permalink) Old 09-24-2017, 06:36 PM
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Sometimes you can never get that to seal right, I've given up on more than one carb that I could never get right. I would make sure your float isn't sinking in the bowl though.
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post #3 of 620 (permalink) Old 09-25-2017, 12:05 AM Thread Starter
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Thanks Mac, I'll order a new float and try that first before looking for a new carb.

98 300 Fourtrax 4x4

Custom built mud bike - Now sold.

2004 Foreman 450S

Fully overhauled (nut & bolt rebuild), 2” lift kit, 28” mega mayhems, ITP delta rims, ES floorboards, 22” LED lightbar, Pyle Bluetooth sound system.
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post #4 of 620 (permalink) Old 09-25-2017, 04:45 AM
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Well just stick it in a little dish of gas or something and see if it floats or sinks. You can hold it down and if it's leaking you will see bubbles. They are plastic so it's not as common as the older metal ones but they can crack. Most likely it's going to be the seat that's the issue but I would just check it before buying a very expensive carb lol


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2015 Honda Rubicant FM7
- 28" Mud Bugs
- Powermadd Handguards
- ODI Grips

2016 Can-am Renegade 1000R XMR
- 31x11" Outlaws
- NPP Dual Dominators
- Monster Power Tuner + Autotune
- ECM Reflash
- TheBOM Mag+ Cams
- TwinAir Air filter
- Delrin Motor Mounts
- Aluminum Valve Covers
- Gorilla Through Shaft
- TigerTail
- Amsteel Synthetic Winch rope
- Cecco Racing Steering Stem Brace
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post #5 of 620 (permalink) Old 09-25-2017, 05:23 AM Thread Starter
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Yeah to right, an OEM isn't going to be cheap at all over here, the needle jet alone was £23.60 I think! Don't think I'll get much change from £300 that's for sure!
I'll have a nose on eBay for a used OEM before diving in for a new one lol

98 300 Fourtrax 4x4

Custom built mud bike - Now sold.

2004 Foreman 450S

Fully overhauled (nut & bolt rebuild), 2” lift kit, 28” mega mayhems, ITP delta rims, ES floorboards, 22” LED lightbar, Pyle Bluetooth sound system.
SamUK is offline  
post #6 of 620 (permalink) Old 09-25-2017, 05:44 AM
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maybe tweak the float adjustment ----- are you sure you don't have flakes of rust coming out your tank, would guess you already have a fuel filter
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post #7 of 620 (permalink) Old 09-25-2017, 06:43 AM Thread Starter
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Yeah my tank is in really good shape inside, I have flushed it out though and replaced the fuel filter.
How do you tweak the float? Warm the plastic somehow?

98 300 Fourtrax 4x4

Custom built mud bike - Now sold.

2004 Foreman 450S

Fully overhauled (nut & bolt rebuild), 2” lift kit, 28” mega mayhems, ITP delta rims, ES floorboards, 22” LED lightbar, Pyle Bluetooth sound system.
SamUK is offline  
post #8 of 620 (permalink) Old 09-25-2017, 07:26 AM
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Have you replaced the float valve sam?

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post #9 of 620 (permalink) Old 09-25-2017, 07:41 AM Thread Starter
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Hey Goober, yes I did, for an OEM valve. I've also cleaned/polished the valve seat.

I even went to the extent of using a magnifying glass when I cleaned the carb the last two times. It's super clean!

98 300 Fourtrax 4x4

Custom built mud bike - Now sold.

2004 Foreman 450S

Fully overhauled (nut & bolt rebuild), 2” lift kit, 28” mega mayhems, ITP delta rims, ES floorboards, 22” LED lightbar, Pyle Bluetooth sound system.
SamUK is offline  
post #10 of 620 (permalink) Old 09-25-2017, 07:48 AM Thread Starter
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Made this on Saturday afternoon. Used a stock tow hitch, cut it in half and capped the end. Turned it upside down to give more clearance and then welded 3/4's of a Large U-Bolt to the top.
Does the job and turned out looking half decent I thought.
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98 300 Fourtrax 4x4

Custom built mud bike - Now sold.

2004 Foreman 450S

Fully overhauled (nut & bolt rebuild), 2” lift kit, 28” mega mayhems, ITP delta rims, ES floorboards, 22” LED lightbar, Pyle Bluetooth sound system.
SamUK is offline  
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