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Discussion Starter #1 (Edited)
Here is my problem: I have a TRX250 Recon es, gas leaks from the drain hose in the carburetor with the drain screw closed. To prevent this, I have cleaned it out with carb cleaner, replaced all o-rings and gaskets as well as replace the needle valve. Float does not have cracks and moves freely though once i turn the gas from off to fuel it begins to drain again.

Does anyone here have a solution to this? I'm out of ideas, and ATV seems to ride as if the engine is flooded which doesn't seem to be a good thing.
 

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Black or brass float?
 

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Is it draining out the bottom or the side overflow?
 

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Number 1 and 12??



 

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Discussion Starter #9
Yes i was thinking that, though it seems my engine becomes flooded with gas due to the open float or something along that.
 

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I have a new (left over) 2007 recon with 10 hours on it and I just experienced this exact same problem. I took it to my dealer (KTM dealer who works on Honda) and the needle valve was clogged. They cleaned the carb and it works perfectly. I think the float was also getting hung up but it sounds like you've already tried these things. If you haven't already fixed the prob, give them a call and ask the serivce manager about this issue and he can give you a more technical description of what he found in my carb. The dealer is B&B KTM in PA 717-898-5764. Please let us know the outcome.
 

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First make sure you know exactly where the fuel is coming from? It may not be as evident until the engine is running if the ATV you have uses the vacuum type of fuel valve? This valve was designed to make sure there was fuel flowing ONLY IF the engine was running. The engine when running creates vacuum and opens the fuel valve for fuel to be able to flow.

It used to be that if a float valve inside of the carb got trash in it and started dumping fuel? It wouldn't stop until the entire fuel tank was empty of all of the fuel inside of it. This created a fire hazard.

The new vacuum system closes off the fuel valve supply once the engine is stopped. So now if there is a fuel leak? It will only leak the amount of fuel that is in the line up to the fuel shut off valve, and the carb bowel itself. This makes things a lot safer over-all.

Several things you can try? One is pull the carb apart AGAIN! (as if this is what you wanted to hear?) remove the float and put it into a small container filled with fuel. Make sure there is enough fuel in the container to completely submerge the float in. Then find something to set on top of the float to keep it at the bottom of this container. Also be careful not to bend of adjust the float adjustment tab when you set this object on the float.

I honestly doubt the float has a hole or crack in it? But this is what you're trying to find out here. Let the float sit in the fuel for 30 min or so to see if fuel does seep into the float? If it does? There is the problem. Replace the float. You'll know if fuel got into the float by the difference in weight (it'll be heavier that it was) or you can shake it and hear the fuel inside of it. OR..You'll see fuel coming out of a hole.

Item number 16 seems to be your problem as Atvfun brought up. Again make sure this float and this numer 16 are connected to each other. There will be a notch in the float for part number 16 to slide into, or there is a retainer spring. Either way these two pieces act together as one. The float moves up and down inside of the carb as fuel flows.

I've seen this happen before, and have NEVER found the small piece of crap causing the problem. So don't be too broken-hearted if you do all of this, and never see the culprit. I do this all of the time, and I've seen this time and time again.

If #16 has the slightest piece of trash or dirt in between the seat? It will leak fuel. I would just buy a new kit that has a new #16 and replace it along with gaskets that come in a carb rebuild kit. By doing this it will give you a chance to clean and inspect the inside of the carb and maybe find a problem that is getting ready to show it's ugly head.

Oh. Does the oil smell like fuel? When a carb leaks this bad, it will dump fuel directly into the crankcase by means of gravity. So any fuel the carb is leaking that doesn't run down the outside of the engine? Is going inside.

If you do smell fuel in your oil? Make sure you change the oil and filter before you go out to your favorite place and run the engine. The fuel cuts the oil down to a point the oil has no lubrication qualities. And this can cause the engine to seize.

Hope this helps some? If it does or doesn't fix the problem? Let us know.
We'll give it another shot. But honestly it's either a bad gasket? Or number 16 with trash or a warn tip on the item #16.
 

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Bustamove, great information. Now u've got me worried that there might be some fuel in my oil. My carb leaked when I started the bike and ran it up and down my drive way once. Then I noticed it was leaking and cut off the engine. I turned the fuel on and off a few times with the engine off and it still leaked. Then I took it to the dealer but I have no idea if they cheked the engine oil...most likely they didn't. If I remove the oil fill cap will I be able to notice a gas smell?
 

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You will notice a faint fuel odor but most of all it will be like a dark creamy color and very loose almost like water. I see this all the time on small engines people ride around with the equipment in their trucks and never shut off the fuel this causes fuel to run and over into the crankcase via intake And they wonder why it wont start
 

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Bustamove, great information. Now u've got me worried that there might be some fuel in my oil. My carb leaked when I started the bike and ran it up and down my drive way once. Then I noticed it was leaking and cut off the engine. I turned the fuel on and off a few times with the engine off and it still leaked. Then I took it to the dealer but I have no idea if they cheked the engine oil...most likely they didn't. If I remove the oil fill cap will I be able to notice a gas smell?
TRX2five0 has the answer you were looking for as far as what to look for if you do have fuel in your oil? His explanation is better than I could come up with.

BUT....to add to all of this. If you haven't changed your oil out yet? I would do so anyway. A few quarts of good oil and a quality filter is a cheap investment when your talking about the heart of your machine.

One issue with these engines is the transmission and engine both use the same oil. And being the transmission creates more viscosity breakdown due to shearing of the oils VII package by the oil running through the gears. It's so important we keep up with the only real protection we have. And that is done by keeping an eye on the proper oil levels, and changing it when it's due.

So basically what I just said was the engine oil if broken down enough through either wear, or gas contamination can cause damage not only to the engine. But the transmission as well because of the loss of it's viscocity.

Oh, some might say ahhh don't worry about it. When the engine gets warmed up, the heat will burn off any gasoline left in the oil. Although that may be true to an extent? Oil can never regain it's viscosity when gas gets in it and thins it out. And oil can never regain viscosity after it's been subject to being to hot. And both of these factors can lead to severe engine wear in a short period of time.

I hate to ramble on about this stuff, but it's my hope a few will understand completely WHY they do something to any mechanical device. This is why I go into detail. I've worked on so many things in my lifetime that it's become habit to explain to customers and mechanics alike why we do what we do. And the big thing is I learn each and every day. Yeah, even by explaining sometimes it just CLICKS.

Good Luck. But you should be fine. (I've seen oil with fuel mix together and run into the air cleaner soaking it. Now that's bad) And they wondered why their engine wouldn't start?
 

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Last weekend I went riding and wile i was wide open on the throttle I was ok but in the creeks and crawls it would die. My friend had to wench me out and when he did my uncle took of my airfilter cap there was about 2 inches of gas in the bottom I guess it was just flooding itself. Does this happen to anyone else.
 

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i think the problem is #16 on the diagram saber6 put on here,my brother in law had the same problem with his recon,he cleaned the carb,but didn't take this pin out to clean the seat for this pin,we took it back apart ,cleaned it out in there with carb&choke cleaner and he hasn't had this problem with it since.
 

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Carb trouble!!

I'm having the same problem with a 2002 350 rancher. I just bought it from a guy that used it to deer hunt. He had it sitting up for a while in north la. Its in great shape but it leaks gas out the overflow tube at the bottom. I have cleaned out the gas tank and have a new carb installed. I noticed some jb weld on the tank valve. He must have cracked the housing and repaired it. Even with the tank valve on the off position, it still leaks from the overflow. Could this broken valve be causing my leak?
 

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You need a new petcock valve if it still flowing when in the off position. But that doesn't explain the carb pouring fuel. That sounds like a stuck float.
 

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So that vacum valve that bust a move was talkin about doesn't pertain to my bike. I was thinking it was maybe something in the valve because i cleaned both the tank and the carb. Plus it a brand new carb.
 

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Anything is possible. I'm not going to say that it's not it.
 
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