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Discussion Starter #1
I have a 450ES that I use on my farm...great machine! Last night I noticed it was leaking gas out of the overflow tube so I pinched it off...should have shut of the petcock...but it was dark and I was tired. This morning the tank was empty and the bottom of the air box was full of gas. I drained the air box, tapped on the carb a bit, and started and drove it...about 4 or 5 minutes...then it died, The airbox has gas in it again...float stuck? trash in carb? How the heck do I get the carb off? I work on my Roadstar carb quite a bit...but know nothing about this ATV...never had any problems with it... I think I need an repair manual ...where is the best/fastest place to get one?
thanks in advance!
Bob
 

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The float in the bowl is stuck if you can get the bottom of the carb off you can service the float. Check in the manual section there should be a download site.
 

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Discussion Starter #5
thanks guys...I downloaded the manual...all 86MBs of it... :) I will try to figure out if I need the take the carb off to fix it. If it's like my bike I need to take it off the first time to replace the cheap bolts that hold it together...the stock mikuni carb bolts strip too easy so I replace them with allen head screws...at least on bike carbs. This is the first time in all of the years I have owned it that anythig has gone wrong...probably dirt from the old gas can...my wife filled it last night just before this happened...I tapped on the sides of the carb several times today but it didn't help...
Bob
 

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Good luck!! Keep us informed..
 

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Discussion Starter #7
will do...
2 questions though...
1) will a 2000 450 carb fit my 2004? they are the same number but 1 ends in an "A" and the other ends in a "C"
2) how the heck do you take of/and put on the plastic body tabs like the 2 that hold the breather box on? I seems to break them off when I pry them up...?

thanks!

Bob
 

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Sometimes those things only go on once, but if you're talking about the black plastic snap in thingies, they should pry open for reuse, though they work better when brand new. You can of course buy replacements for not much money.

I would expect that machine has a fuel filter somewhere on it, so dirt in the gas can probably didn't do it, and that would tend to clog up the jets rather than stick the float. If you are going to have the machine sitting around not being used it is best to turn the fuel off and let the machine run until it runs out of gas, that way the carb will stay cleaner.
 

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Discussion Starter #9
thanks...
I will have to get some of the black plastic things because only one of the 3 that I snapped out yesterday is still good...
As far as using the 4 wheeler...we live on our 100 acre cow/chicken farm and use it several time a day every day...and have since it was bought new in 2004... :)
I will figure out how to get the carb off...right now it seems like it will take longer to get the breather box off than the carb... LOL.
thanks!
Bob
 

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It would probably be a good idea to use some seafoam fuel additive in your gas a few times a year. Even if you use the machine often, you may not run a full tank through it that often, so it might get old. Not sure how much you use it, but it won't hurt to treat your fuel occationally to help keep the stuff as clean as possible without manual cleaning.
 

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Discussion Starter #11 (Edited)
you're right...I run it thru my bike once in awhile...
thanks,
Bob

-update- I just found out that when it drained the gas tank yesterday, that it also filled the air box and then ran from there into the engine...so the crankcase is full of gas/oil...I actually drove it that way about a half mile out to check a corn feeder yesterday...it died on the way back. I will drain the oil and change the filter...hopefully nothing else is messed up.

-update- I didn't take the carb all of the way off but did pull the bottom off of it. I sprayed carb cleaner in it and it looks good so I put it back together. I plan on putting everything back together tonight if I get home from work in time...then it will be change the oil/filter...run a week, and change the oil/filter again...at least that's the plan. I also think I may stick a small air filter on the crankcase vent and not reattach it to the air box...it seems like a poor design that allows the overflow gas to flow thru that hose into the crankcase...?
 

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Make sure the carb overflow hose is not plugged and it shouldn't leak into the air box. As for the screws that hold the carb bowl on, make sure your screw driver fits the screws real tight. Different tips and even different brands with the same tips are different sometimes. If one won't fit good, then try another brand. Before you try to loosen them, put the screw driver on the screw and give it a sharp tap with a hammer or rubber mallet. Obviously, the carb will need to be off to do this. A lot of times this will jar the screw and help to loosen it. If you do strip the head out, cut a groove accross the center of it with a dremel and cut off wheel and use a flat or slotted screw driver to get it out. If you don't have a dremel, you can sometimes use a hack saw, but it is a little harder to do, but can be done. I always take them off to work on them anyway, because it is a lot easier, for me anyway. It sounds like your float is just stuck. Take it out and pull your needle valve out and make sure it is clean and make sure the hole where it goes is clean and don't have any debris in it. Better to blow it out with an air hose if you can. Be careful when you pull the float out that the needle valve don't fall out as it is usually attached to the float with a little wire clip. While you have the float out, if it is plastic or metal, make sure it don't have a tiny hole in it. Sometimes you can shake it and listen for gas to slosh around inside it if it has a hole. I doubt that it will be metal, because they haven't used metal or brass in carbs in a long time. Sometimes they will be made of some type of solid plastic or material of some sort. Hope this helps. Good luck with the repair.
 

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Discussion Starter #13
thanks for the great reply...

I got it back together and started it...no smoke and it seems to run good but I messed with the throttle stop screw before I knew what I was doing...now it won't idle... which it always did great before. It was dark when I got it back together so I might have something hooked up wrong...

any idea where a good starting place is for the TS screw?

thanks again.

Bob
 

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If it is just the idle screw, then just turn it in until it idles at the speed you want. If it is a air screw, start at about 2 or 2 1/2 turns out from the all the way in position. With the engine running, slowly turn it in until it starts to quit. Then slowly turn it out until it starts to run rough. Now turn it to the midway point between where it tried to quit and where it tried to run rough. That should be close. If you have to adjust the air screw, you may have to readjust the idle screw.
 

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Discussion Starter #15
It was the idle screw...I turned it all of the way in and then backed it out 1/2 turn...problem solved...however...I only dropped the bottom off the carb and sprayed it out...the leaking is back so I have dirt under the needle valve apparently...I will pull it off again and actually take it apart this time I guess...I would hate to have to remember to turn the gas off every time I parked it...
thanks again.
Bob
 

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Discussion Starter #16
OK...everything is great now...It was nice outside so I took the carb back off...completely off this time. I cleaned the fuel bowl and then took the float off and cleaned the float valve and seat real well and blew out the fuel intake hole...and put it all back together. I did notice that a couple of the small hoses attached to the carb were cracked where they attached so I clipped them shorted and fixed that too. Got the carb back on and everything tightened back down...cleaned the breather foam filter real well with K&N cleaned and then a bucket of hot water...anyway it started with just a bump and no more leak from the overflow...so my wife is happy...total cost was "$0"...I already had a new oil filter and oil...
thanks much.
Bob
 
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