We finally got some snow so I could try this sled out I had a few issues, first it had an intermittent bog just when you didn't expect it so I stopped and unplugged the tss, that fixed the bog. Then it ran okay the rest of the day except for it seemed to load up when running the first 1/4 to 1/3 throttle but it would clean up right away when the throttle was opened past half way.
Then there was the massive fuel consumption? I could smell raw fuel while going slow ( when it seemed like it was loading up ) I stopped a couple of times to look for a fuel leak but I couldn't see anything obvious but our day was cut short after 20 miles when I realized the fuel gauge was on empty so we headed back to the truck 3.6 miles and it ran out loading it on the trailer. So that's like 2 mpg. now I am hoping it has a fuel leak but where?
It has #320 main jets and the plugs look a tad lean which it should have been since it 30+ degrees and I was riding between 9,500 and 11,000 ft.
The sled seemed to ride and handle okay even with the rear suspension mod.
One time I had similar fuel consumption on my '01. Turned out, when I had reassembled after cleaning the carbs, I accidentally ran the fuel supply line in front of the carbs, instead of over them. The line was resting on the jack shaft and the shaft wore a whole through the line. I lost a lot of gas quickly, and was very lucky that she didn't burn up.
There are water traps connected to the float bowl on the carbs. Chances are they dry rotted and are leaking. Just replace with new line. Easy fix if that's it.
Yes. If they are the flatslides like my 800 they have the water traps just as tcat said. Also even tuned right my 800 is by far the thirstiest sled I have. So I don't know if it's the carbs or what.
Well, I have the flat slides on my 2000 ZRT 1004 and was getting around 6.0 mpg. The first thing I did was to replace the float assy o-rings with the new and improved o-rings and this helped but #3 cyl was always running richer then #1 and #2. I removed the rack and removed all three float assy's and used a magnifying glass and inspected the carb chamber that the float assy o-rings slip into. There were slight casting flaws in all three of the chambers which made me think that maybe fuel was leaking by the new o-rings when the needle seated. So I made gaskets to fit under the float assy's just to make sure no fuel was leaking by the o-rings. Well lo and behold I am now getting over 8.0+ mpg and the EGT's evened out. Cat happy
You know Jeff, I used to build drag and stock car engines so I always had different thickness's of gasket material laying around so I just dusted off the thinnest I could find and let it buck. It was just hard paper material so I don't know how it will hold up but I bet if you search the internet and ask for gasket material that will work with gas and oil you could come up with something. If you find some good stuff let me know.
This sled has the round slide carbs and they aren't on a rack, I looked at it a couple of times and I didn't see anything leaking. Also I had run it in the garage several times the past couple of weeks and it didn't smell like gas and it sat in the garage full of fuel the nite before I rode it so I'm thinking it may have developed a leak as suggested but I can't look at it now because I left it up where I ride.
Sounds to me like you have dirt in the needle & seat being its loading up and using a ton of gas. If lean on top they probable tried to lower the float height to cure the loading up. Tear carbs apart and clean. Look over needle & seat, Make sure all floats float in gas as I have seen a few that wouldn't and had to be replaced. I have also seen floats stick on the rod they slide on. Reset float height when assembling and you should be good to go. Also check the water trap & fuel lines like mentioned previously and as long as you are working on it check vacuum line from fuel pump to crankcase. I would replace all the fuel lines and filter as well as the sled is almost 20 years old. My 97 T-cat has two pulse line pick up at the crankcase and one is plugged. The plugged one has a rubber cap that is cracking and is need of replacing. Check that as well.
Yah Al, I installed the R/B new o-rings on the float assy and still had uneven EGT readings at idle so I cut out three gaskets that I installed between the float assy and the carb body and everything evened out. I called Lon Peterson (a friend) at Thunder Products and wondered if he would be interested in making these gaskets for the TM carbs and his response was that 99% of riders don't know they have this problem so he opted out.
I got a chance to look at the T-CAT today and tcat446 nailed it, the water drain on the PTO side carb was leaking and it literally fell off when I touched it. I didn't repair it yet but at least I know what the problem is. Thanks.
Al, I had a 2001 ZR 800 that got bad gas mileage (6-7) so I removed the TM 40's and the float assy o-rings were hard so looked up the part # on Brown's and the new number (6505-87) replaced three other part #'s. As you know when there is a R/B number that means new and improved. Mileage went up to 12.
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