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Discussion Starter #1 (Edited)
you can skip to the end unless you want the whole story. I like to ramble aimlessly. It makes me feel better about my sh----y troubleshooting steps :grin


Last year I got my first 4x4 300. I'm hooked. Thing runs like a top, starts amazingly, it's sexy, and best of all it goes anywhere!

So through a series of recent trades and what have ya I wound up with a newer (1997) 300 4x4 in addition to the first. Thing ran alright halfway choked, not quite as clean as my 93 but has a winch. I left it with my brother for storage and he used it a few times but he told me it left him stranded out in the yard. So I clean the carb and leave it out at his place. He reports back that the carb cleaning was spot on and the thing runs awesome - no choke fires right up and no stutters or hesitations.

fast fwd a couple weeks I'm out there ripping around on it. It starts backfiring and not responsive to throttle and it leaves me stranded. first thought was it was flooded. Let it sit 30 mins. It fires up but not for long. sputters out and dies. then it occurs to me that I wasn't the last person to fill it up....... yea, it shoulda been my first thought but it wasn't the problem sooooo :grin



Anyway I should have pulled the fuel line then and there but..... I let it sit a couple hours and it fired up and ran flawlessly another 20 mins... and I'm stranded again when it dies!!!! ...WTF!


I decided to take it home where I let it idle.. (well kinda.. i held it open for a couple mins lol) for a half hour when it sputtered out and died. so I pull the fuel line and there's nothing but one single drip (fuel shutoff pointing at the sky and the fuel cap to "on") I then took the fuel cap off and got a couple drips but no flow. I had the cap off a couple mins and it didn't get more than 5-6 drips. I thought it was strange it died though cuz the fuel line had some gas in it! leaked freaking everywhere as I let go of it not even thinking itd be anything but dry seeing as nothing's coming out of the fuel shutoff!!

I don't get it.
Is there another vent on the tank?
Do I need to clean the petcock?
is my tank shot?


I appreciate any help or insight. I'm at a loss. I'd swap tanks on my older one but I don't think they're interchangeable because it looks like Honda changed the frame / snorkel design somewhere between 93 and 97
 

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Yep, take the petcock out of the tank and either clean the screens and put new seals in the valve assembly, or replace the entire thing with a new one.

Welcome to the forums!
 

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Yep, take the petcock out of the tank and either clean the screens and put new seals in the valve assembly, or replace the entire thing with a new one.

Welcome to the forums!
what he said ^^^ !. the pick up screen, which goes up in the tank from the petcock might be clogged ?, or..there is also a round filter inside the petcock bowl under the bottom of the petcock.
 
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Registration includes treats: Get 'em HERE.

Have fun!
oh man, I thought you were giving out free cookies ?, so I clicked on it, damn service manuals !..lmfaooooo.
 
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You do have a clean fuel filter on it right...?
ehhhh..most from factory do not have an inline fuel filter ?, most owners add them on their own :). only filters they come with is the pick up screen in the tank from the petcock, and the round filter that's in the petcock bowl.
 
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I deleted my post above cause you had the best answer... guess I had better put it back? I can arrange for cookies too if you like! LOL
 

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I deleted my post above cause you had the best answer... guess I had better put it back? I can arrange for cookies too if you like! LOL
lol, nah..your post was fine, no worries.
 

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Discussion Starter #10
Thanks for all the responses!

I guess I don't see how it could be the petcock if it runs fine but i guess that makes sense. it's filling the bowl. running off that and then when the trickle can't keep enough in then it dies.

bummer, it's got a good deal of fuel in it. I hate siphoning gas I already paid for.....
 

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Thanks for all the responses!

I guess I don't see how it could be the petcock if it runs fine but i guess that makes sense. it's filling the bowl. running off that and then when the trickle can't keep enough in then it dies.

bummer, it's got a good deal of fuel in it. I hate siphoning gas I already paid for.....
pretty simple here, start by turning the fuel off, remove the bowl from the petcock ( 10mm wrench or socket ), clean the filter out if dirty ?, as well as the bowl ), see if that works ?, if not ?, you will need to remove the petcock from the tank, so you can see if the pick up filter is bad ?, clogged ?. also , MAKE SURE YOUR TANK IS FUEL OF GAS !!, yes..i have seen owners sware there was fuel in the tank ?, and they was trying to run it on '' on '' ?, instead of '' reserve'' ?..lol.
 

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last but not least ?, your float needle can be sticking closed ?, but I would start at the petcock first !, and work my way to the carb :).
 

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Discussion Starter #13
thanks shadetree

yea I should have switched it to res when i had the line off and no fuel. I didn't realize the petcock came apart without removing it. *I've been up for 20 hours, I should probably clarify you are saying that I can take the petcock apart with fuel in the tank as long as the shutoff is horizontal?

anyway, yea, It's not a big deal. I just wanted to add the siphoning joke that probably wasn't half as funny as I thought it was :grin
 

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thanks shadetree

yea I should have switched it to res when i had the line off and no fuel. I didn't realize the petcock came apart without removing it. *I've been up for 20 hours, I should probably clarify you are saying that I can take the petcock apart with fuel in the tank as long as the shutoff is horizontal?

anyway, yea, It's not a big deal. I just wanted to add the siphoning joke that probably wasn't half as funny as I thought it was :grin
your welcome. yes, you can take the petcock bowl off the tank when you turn the fuel off. but as you know, or will know !..lol. you cant take the whole petcock off the tank !..lol. but by turning the fuel off,yes, you can remove the bowl from the bottom :).
 

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I think I've been up for about 30 something hours ?..wanna trade ?..lmfaoooo.
 

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I would put a clear inline fuel filter on after the petcock before the carb, makes it easier to change the line to the carb if it gets hard, or pull the tank for valve adjustments or cleaning. :D
 

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Discussion Starter #17
Lol nope, No trades! I've found 15-16 hours is the ideal for me and anything after that I'm just worthless and then the next 3 days I'll sleep 4 extra hours each.


Yea I removed the petcock from a foreman 400 I had (the wife's bike, had more problems then a Polaris) just didn't know the petcock came apart without taking the whole thing out. So I'll give that a try.

I'm planning on replacing the fuel line and I'll add a clear filter. Ill have to put one on my 93 as well.

I'm really looking forward to not having more issues with this bike. We're planning on taking them out with us Memorial Day and if I didn't have to push it back to camp maybe my wife would finally be happy with it! (The crappy foreman was hers and when we got this and found out it had problems she's just pissed at the world. ..at least a 300 is worth fixing. Lmao
 

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Lol nope, No trades! I've found 15-16 hours is the ideal for me and anything after that I'm just worthless and then the next 3 days I'll sleep 4 extra hours each.


Yea I removed the petcock from a foreman 400 I had (the wife's bike, had more problems then a Polaris) just didn't know the petcock came apart without taking the whole thing out. So I'll give that a try.

I'm planning on replacing the fuel line and I'll add a clear filter. Ill have to put one on my 93 as well.

I'm really looking forward to not having more issues with this bike. We're planning on taking them out with us Memorial Day and if I didn't have to push it back to camp maybe my wife would finally be happy with it! (The crappy foreman was hers and when we got this and found out it had problems she's just pissed at the world. ..at least a 300 is worth fixing. Lmao
all Hondas, or and brand for that matter, ( but i'd rather have a Honda ) are great atvs, IF YOU TAKE CARE OF THEM !..LOL they must be gone through now and then, oil filters, air filters, fluids, grease, you name it
 

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Discussion Starter #19
That foreman wasn't worth what I sold it for. I'll just say that..

Anyway, I got the petcock out and the lower level (reserve portion?) is collapsed

I'm guessing that is adding to the problem however everything seems clean ish and has poured freely when I switched it to reserve. I think stupidity was a factor on this one..

Anyway, the collapsed screen kinda bothers me. Is that common for the 300s?

i doubt my Honda dealer would have the screen in stock.
 

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That foreman wasn't worth what I sold it for. I'll just say that..

Anyway, I got the petcock out and the lower level (reserve portion?) is collapsed

I'm guessing that is adding to the problem however everything seems clean ish and has poured freely when I switched it to reserve. I think stupidity was a factor on this one..

Anyway, the collapsed screen kinda bothers me. Is that common for the 300s?

i doubt my Honda dealer would have the screen in stock.
that area has nothing to do with the reserve. only lever, and the pick up screen that goes up into the tank determines when on reserve ?. that filter/screen goes bad a lot over the years, not really needed if you want me to be honest ?, if ya put an inline filter in between the petcock and carb ?, you could run it like that with no problems. also, even if Honda does keep them in stock ?, i'm sure that thing would cost you about 20 bucks or more ?..lol. your main filter is the filter that goes up from the petcock, into the tank !, if that gets clogged ?, fuel won't flow at all.
 
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