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Discussion Starter · #1 ·
OK, so my '02 400ex started fouling plugs so I rebuilt the carb. There was no fuel leak at all prior to the rebuild. Of note i forgot to take out the drain screw when i dipped the body, but again it wasnt leaking. So after the rebuild it ran great, no issues, but about 10 min after shutting it down fuel just starts running out of the drain tube. I figure gunk in the needle so I took it back apart and put in the new needle that came in the rebuild kit (i didnt use it before) and sprayed the seat out. Again it runs great, again 10 minutes after shutting it off fuel just starts pouring out. I didnt think it was the drain plug since it wasnt leaking before the rebuild but i took it back apart, cleaned the drain plug and put the prior needle back in and hosed it down again with carb cleaner... 10-15 min later, same thing happened!? Again it wasnt doing this before i rebuilt it, and its running great. Anyone have any idea what i could have screwed up during the rebuild that would allow it to run great but have this problem? Thanks -
 

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What brand rebuild kit did you buy? The cheaper kits have float problems. Did you use the new float privided the kit had one? And also could there be dirt or junk getting into the gas tank or fuel line when you take the tank off? Anything can get into the needle and hold it open. I had a guy use grease to hold the bowl gasket in place one time and the grease would get into the needle and make it leak after a short ride. He was having a hard time getting the bowl seal to stay in place and thought grease would break down into the gas and not be an issue. Needless to say he was wrong lol.
 

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Discussion Starter · #4 ·
OK, I think Im an idiot. All my trouble shooting searches talked about the needle getting hung up, I thought they were taking about the needle jet so thats the one i kept switching out. Now I see the float valve is sometimes called the float needle - correct? I replaced the float valve with the one from the cheap kit I got. I'll look at it, if I cant see anything hanging it up Ill just put the original back in it since again, it wasnt leaking before. Thanks a lot folks -
 

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Not an idiot! Also make sure like ^^^ranger said that fuel supply line and tube can get a particle in there which will keep the float valve from seating. Even a hair from the swabs you might've used to clean the tubing
 

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Discussion Starter · #7 ·
Resolved! Sure enough, it was the cheap rebuild kit. The little rod at the very top of the new float needle was about 1.5-2mm longer than the original. This caused it to bind up on the plastic part of the float just above it. it wasnt able to hang loose and so it bound up and didnt seat. I put the old one back in, it hung freely, and no more leak. I wonder if I can get my money back? Thanks for the help! By the way, the guy I bought this from 3 years ago told me he rejetted it for the k&n and full hmf pipe... he didnt, thats fixed now too.
 
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