[Brucebwp2]

So I had bad gas in my ATV and pumped out as most as i could then i took the fuel pump off to clean it but then i noticed no gas is coming out of the lines that where connected to the pump. I added some gas to the tank and turn the petcock valve from Res to Off to On multiple times but not a drop comes out. I can blow into one line and hear bubbles when its on the Res an Off setting but no air goes through the other line. Is this a clogged Petcock issue?

 

[retro]

Test the fuel pump to make sure it runs and pumps fuel.

 

[retro]

And yeah, it sounds like fuel is not getting through the petcock. How long did it sit with fuel in it?

 

[Brucebwp2]

It hasn't been ran since last summer but the gas has been in it a couple years. The fuel filter on the pump was stopped up pretty good so i'm going to get a replacement for that. How can i test the fuel pump to make sure it works before putting it back together?

 

[retro]

Look in the service manual for proper polarity... you can jump battery voltage to the pump to see if it runs and sounds strong before ya put it back together. You'll need to remove the fuel tank and flush that out real good too. Flush the petcock, lines and sub-tank too. The 420s are real fussy when it comes to rotten fuel anywhere in the system. Fuel pumps generally die right away. Gotta be super thorough and picky when ya work on them. I imagine the injector, IACV, TP/MAP and throttle body need a thorough going through for cleaning too. You'll need to re-initialize the TP/MAP after you get it back together. You might chase gremlins for quite a while if anything is skipped or given a half-effort.

 

[Brucebwp2]

Okay i will do that. Got the tank off today an removed the petcock but turns out the petcock is broke off at the base inside the tank ontop of being clogged up. Have a new one and a new fuel filter coming in the mail. I think the pump may have died before it could pump to much of the gas through the lines but i will double check everything to be sure. Thank you.

 

[Brucebwp2]

Okay so turns out it was a combination of bad fuel and the fuel pump being bad, It is running good now but i had to put a petcock on the gas tank but it was a cheap Chinese one and it is leaking.
I'm going to order a OEM one an put it on but was wondering if there was a torque specification for the bolts to put it onto the tank? I cannot find it anywhere in the manual.

 

[retro]

Make sure the petcock O-ring gasket is in good condition, not squeezed out, no cracks forming, etc. Then put some anti-seize or grease on the 6mm bolt threads and push them through the setting collars and snug them up. Just run them in until they stop and are tight. It doesn't take much to hold the petcock on... the most important thing is lube for the threads because you'll have to take those bolts back out of there someday.

 

[Brucebwp2]

Got everything back together and ran it yesterday but now i am encountering a problem where it will sit and idle just fine and even drive around just fine but on occasion while driving it will suddenly lose power bog down and shut off. Yesterday it would do this and start right back up and rev just fine but soon as i shifted into gear and pushed the throttle it would just shut off.
After a while of driving it did this less and less but still does it from time to time even if i shut it off for a couple minutes then start it back up as soon as i shift into gear an push the throttle it will shut off but it doesn't do it every time. Today i was riding it and had it shut off on me after about 10min and driving and it would turn over but not start until i turned the key off then turned it back on, worked just fine after that for another 20 min then on the way back it shut off and would not start until i cycled the key on an off once again then ran just fine all the way home.
Things i have checked are the vent lines to the tank to make sure they are not clogged or pinched and i took the gas cap off and ran it only to have it shut off still.

 

[shadetree]

chances are, your fuel injector is dirty/clogging up.

 

[Jeepwm69]

Put a little seafoam in it and run it and see if it clears up.

If it doesn't, you might have to change out the fuel pump filter, or even the fuel pump. The 420 fuel pumps don't do well if you leave old gas in them for any prolonged period, especially ethanol gas.

 

[Brucebwp2]

Okay thank you for the suggestions. And i did change the fuel pump and fuel filter, Upgraded to the new side style fuel filter.

 

[Brucebwp2]

Turns out after putting everything together the lever for the Res tank was on upside down so when in the On position it was actually using the Res thats why it would shut off, Everything seems to be fixed now.

 

[retro]

Thanks for following up and letting us know! Have fun!

 

[shadetree]

Turns out after putting everything together the lever for the Res tank was on upside down so when in the On position it was actually using the Res thats why it would shut off, Everything seems to be fixed now.

I could be wrong on this ?, but..from what little I know about the selector knobs on fuel tanks, if you installed the knob facing the wrong way, so it was set to reserve instead of on ?, this should only make a difference when running. what I mean is, if you set the knob to reserve, when you thought it was on ?, all you would do is run out of fuel, because you would never get to a point where it would shut off, then switch it over to reserve to get it running again. have I lost you yet ??. now..if you installed the lever to go from on to off ?, then yeah..would make sense. the only difference between reserve and on is that you would never get to that point where you would be going along, it ran out of gas, and you switch it over to reserve to keep going, in other words, no reserve, because you ran it out of fuel because you were always in reserve position. I hope this makes sense to ya ? .