[Thaddeusss]

Hey all, I hope you can help... I’m trying to help a friend troubleshoot their 08 420 rancher that caught fire due to a mouse nest and associated wiring damage. They got the fire out pretty quick and kept the melting to a minimum... it did run immediately after but now won’t start. Bigger problem, though, is that fuel is _pouring_ into the airbox. I’m not there in person so I can’t quite tell where it’s coming from but I’ll try to post a photo they sent me. It’s a port next to the air filter-to-throttle body connection, on the right side of the machine I think.

Fortunately the fuel problem seems to have been caused by or is unrelated to the fire, as there obviously wasn’t a bucket of fuel sitting there when the fire happened or the ATV would have been toast!

Any ideas what’s causing this?

 

[shadetree]

sorry, but that pic don't show me anything that stands out to see ??..lol.

 

[shadetree]

just guessing..i would start at the fuel pump, and work my way to the throttle body along the fuel rail..and see here its leaking from ?.

 

[retro]

There's likely some mis-communication between the owner and yourself concerning the leaky fuel source, since the airbox gadget ID you are asking about is probably the crankcase vent, or the ambient air temp sensor. Someone who understands what they are looking for should probably take a look at the bike. You can find a link to a copy of the service manual from the manuals forum.

https://www.hondaatvforums.net/foru...nual-help/50817-service-manual-downloads.html

 

[retro]

There's likely some mis-communication between the owner and yourself concerning the leaky fuel source, since the airbox gadget ID you are asking about is probably the crankcase vent, or the ambient air temp sensor. Someone who understands what they are looking for should probably take a look at the bike. You can find a link to a copy of the service manual from the manuals forum.

https://www.hondaatvforums.net/foru...nual-help/50817-service-manual-downloads.html

 

[Thaddeusss]

I appreciate any advice, but maybe look a little closer? I took this screenshot from a video they sent me. If you look close in the upper left of the photo, the dark space next to the air filter... you can see fuel pouring out in a 1/4” solid stream into the fuel-filled bottom of the airbox.

If that’s the crankcase vent, why is gas pouring out of the crankcase in a solid stream?

This only happens when the key is turned on. I can hear the fuel pump running in the video.

I’m asking for assistance in figuring out what path the fuel might take to get to this spot.

I’m trying to help these folks because they live remotely and their machine has snow tracks on it... they can’t take it somewhere to get it looked at anytime soon!

Here’s a clarified photo with an arrow for you.

 

[Thaddeusss]

Thanks for the link to the manuals, I’ll dig through that and see if I can find what I’m looking for.

 

[GirlsRideToo]

I appreciate any advice, but maybe look a little closer? I took this screenshot from a video they sent me. If you look close in the upper left of the photo, the dark space next to the air filter... you can see fuel pouring out in a 1/4” solid stream into the fuel-filled bottom of the airbox.

If that’s the crankcase vent, why is gas pouring out of the crankcase in a solid stream?

This only happens when the key is turned on. I can hear the fuel pump running in the video.

I’m asking for assistance in figuring out what path the fuel might take to get to this spot.

I’m trying to help these folks because they live remotely and their machine has snow tracks on it... they can’t take it somewhere to get it looked at anytime soon!

Here’s a clarified photo with an arrow for you.

My answer may be totally crazy, but did someone hook the lines back up after the fire?? Did they connect the fuel line/hose into the air box in the hole meant for the IAT sensor? The tubing on both are about the same size?? However, the sensor would not fit on the carb. LOL. Is it possible they pulled the sensor off after the fire and mistakenly put in on the fuel line??

 

[shadetree]

I appreciate any advice, but maybe look a little closer? I took this screenshot from a video they sent me. If you look close in the upper left of the photo, the dark space next to the air filter... you can see fuel pouring out in a 1/4” solid stream into the fuel-filled bottom of the airbox.

If that’s the crankcase vent, why is gas pouring out of the crankcase in a solid stream?

This only happens when the key is turned on. I can hear the fuel pump running in the video.

I’m asking for assistance in figuring out what path the fuel might take to get to this spot.

I’m trying to help these folks because they live remotely and their machine has snow tracks on it... they can’t take it somewhere to get it looked at anytime soon!

Here’s a clarified photo with an arrow for you.

yikes !!. I must agree, it almost looks like the fuel line is running from the pump straight into the air box, and not even hooked to the fuel injector fuel rail ?!.

 

[retro]

@Thaddeusss

I hope that bike is not parked inside a garage that is attached to their house!?!? Best advice I can offer since they live remotely, is for you, or someone near them... to force-feed them the PGM-FI fuel section of service manual. Better yet, someone who knows what they are doing should probably go take that bike away from them, cause it looks like they are attempting to cobble it back together rather than replace all damaged parts with the appropriate OEM replacements.

 

[Thaddeusss]

I got them to send me another video, it appears that for some reason when the ignition is on, the fuel injector just goes wide open and sprays fuel nonstop. Not sure how fuel was finding its way out that port, but when the filter was removed it just poured out the throat of the throttle body instead.

 

[retro]

That injector is probably broken open. Water in the fuel that froze...?

 

[LedFTed]

Water in the fuel that froze...?

doe's that involve the dreaded ethanol gas?

 

[Thaddeusss]

I’m fairly certain the fuel problem didn’t exist prior to the fire. They were driving the machine when it caught fire, mouse nest in the wiring and shorted, chewed wires caused the fire. Ignoring the fact that it doesn’t run with fuel dumping out like that, had there been a puddle of fuel in the airbox when the nest caught fire, the machine wouldn’t be much but a melted wreck anymore.

 

[retro]

Did they get it fixed yet?