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Old 03-17-2012, 08:23 PM   #1
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Fuel Flowing From Overflow (After Rebuild)

Alright, I'm on to the next repair on my 2005 Arctic Cat 400 4x4. Gas is flowing from the overflow tube of the carburetor. I've had the same problem with a few other ATVs (I noticed this is the same type of carb as a Kawasaki Bayou 300), and the fix has always been to clean the little float needle thing that is attached to the float. Every other time I've had this issue, this was gummed up and stuck, and cleaning it fixed the problem.

I think this may be a different issue. The guy I just bought it from said he had a shop rebuild the carburetor last summer. After taking it apart, I see that the float needle is still shiny new. My theory is that the shop that rebuilt the carb failed to properly adjust the float height, overflowing the bowl. How do I adjust the height of the float to decrease the amount of fuel in the bowl? My Bayou service manual (same carb) says to decrease float height to increase fuel level and vice versa; I'm having trouble wrapping my mind around this as it seems to be back-asswards. Is this actually correct, and I'm misunderstanding how the fuel flows through the carb?

You'll have to forgive me; I'm still new to carburetor work. I appreciate everyone's help!
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Old 03-17-2012, 09:03 PM   #2
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I can't answer your problem as I dont completely understand the workings of a carb. Go to mymowerparts,com and download a free service manual. It will tell you all you need to know.
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Old 03-18-2012, 01:06 AM   #3
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I believe I've figured out how to adjust it, and why it seemed backwards. The adjustment instructions don't specifically say to do it, but paying attention to the diagram, you have to hold the carburetor upside-down to adjust the float! Float height is measured from the upside-down position, from the outside edge of the float to the mating surface where the carb body meets the bowl.

Lets say you are holding the carb upside down, and you "raise" the float height (say from 17mm to 20mm). When you turn it right-side-up, the float will have a shorter distance of travel before it pushes in the shut-off pin into place. Therefore, raising the float height will decrease the fuel level (and also vice-versa).

This is a common problem with these carbs (its the third Keihin carb I've seen that poured out gas), and I think this would be good information to have. Its apparently a common carb, seeing as how both of my Kawasaki Bayou 300 bikes had it, and now my Arctic Cat has one. I may do a video guide on it sometime with my new camera and post it to YouTube so others will have a reference. I've Googled for days, and I've not had much luck finding out information on this carb's internals.
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Old 03-18-2012, 02:00 AM   #4
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I went through this float adjustment my self. The float height should be checked with the carb on its side and with the float just touching the needle but not compressing it. You measure from the bottom of the carb to the bottom of the float which should be 17mm. Another way to do it is remove the float bowl cover and with the carb at eye level blow into a hose connected to the fuel inlet and the float should start to close the needle at the point of the float itself being level with the bottom of the carb. Same as 17mm.
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Old 03-18-2012, 07:29 AM   #5
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 Quote: Originally Posted by Majoraslayer View Post
I believe I've figured out how to adjust it, and why it seemed backwards. The adjustment instructions don't specifically say to do it, but paying attention to the diagram, you have to hold the carburetor upside-down to adjust the float! Float height is measured from the upside-down position, from the outside edge of the float to the mating surface where the carb body meets the bowl.

Lets say you are holding the carb upside down, and you "raise" the float height (say from 17mm to 20mm). When you turn it right-side-up, the float will have a shorter distance of travel before it pushes in the shut-off pin into place. Therefore, raising the float height will decrease the fuel level (and also vice-versa).

This is a common problem with these carbs (its the third Keihin carb I've seen that poured out gas), and I think this would be good information to have. Its apparently a common carb, seeing as how both of my Kawasaki Bayou 300 bikes had it, and now my Arctic Cat has one. I may do a video guide on it sometime with my new camera and post it to YouTube so others will have a reference. I've Googled for days, and I've not had much luck finding out information on this carb's internals.
Could have saved yourself days!!! Lol look in the pinned section for jetting 101 lots of links and good info
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Old 03-18-2012, 12:10 PM   #6
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This is anic write up about setting your float level, might helpyou some.

How To Set Your Motorcycle Carburetor Float Level (more commentary).
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