Fuel leaking from Carb overflow tube 450S - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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Old 12-31-2009, 11:30 AM   #1 (permalink)
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I recently purchased a 2000 450s foreman that had been sitting for quite some time from a friend. Before I picked it up he said he discovered it was leaking gas from the overflow tube on the bottom of the carb float bowl. He took it to his local Honda dealer who cleaned the carb and replaced the float needle valve total cost $165.00. I picked it up and rode it for a little while and discovered it was again leaking gas from the overflow. Rather than return it to the dealer who did the service (150 miles away) I took it to a local dealer who again cleaned the carb, replaced the needle valve for another $150.00. After 1/2 day of riding it was again leaking fuel. I returned it to the dealer for warranty only to have them tell me the carb is no good and they would replace it for $650.00. I said F##@k that and called one of the advertisers on this board and ordered a new carb for $275.00 list price ($450). I removed the old carb, cleaned the gas tank, and installed the new carb. Everything worked fine for 2 days of riding when once again the new carb was leaking from the overflow. I again removed the new carb and sure enough their was a couple specs of crud on the valve seat. This time I cleaned out the crud, again cleaned out the gas tank and replaced the fuel line and installed an in-line fuel filter. I have ridden it for several days and problem solved.
Lessons learned
At the end of the day Always shut off the fuel selector and run the fuel from the carb until the machine stops
Always store the machine with the fuel valve off as this leak could have been a major fire hazard by leaking a couple gallons of fuel on the garage floor.
If you will not be using the machine for a while add fuel stabilizer to the gas tank and be sure to turn off the fuel valve and run the machine until the engine stops.
If you have a similar problem be sure to clean the tank, install new fuel lines, and add an in-line fuel filter.

By the way the old carb is fine after I cleaned crud out of the needle valve seat.
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Old 12-31-2009, 12:47 PM   #2 (permalink)
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I have had a few of the older 400/450 carbs that the float pin worn the housing on the carb it sits in and leak gas. They can be repaired also by a mechanic that wants to or knows how to fix it.
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Old 02-23-2010, 06:38 PM   #3 (permalink)
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QUOTE (tracyduke @ Dec 31 2009, 05:30 PM)
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I recently purchased a 2000 450s foreman that had been sitting for quite some time from a friend. Before I picked it up he said he discovered it was leaking gas from the overflow tube on the bottom of the carb float bowl. He took it to his local Honda dealer who cleaned the carb and replaced the float needle valve total cost $165.00. I picked it up and rode it for a little while and discovered it was again leaking gas from the overflow. Rather than return it to the dealer who did the service (150 miles away) I took it to a local dealer who again cleaned the carb, replaced the needle valve for another $150.00. After 1/2 day of riding it was again leaking fuel. I returned it to the dealer for warranty only to have them tell me the carb is no good and they would replace it for $650.00. I said F##@k that and called one of the advertisers on this board and ordered a new carb for $275.00 list price ($450). I removed the old carb, cleaned the gas tank, and installed the new carb. Everything worked fine for 2 days of riding when once again the new carb was leaking from the overflow. I again removed the new carb and sure enough their was a couple specs of crud on the valve seat. This time I cleaned out the crud, again cleaned out the gas tank and replaced the fuel line and installed an in-line fuel filter. I have ridden it for several days and problem solved.
Lessons learned
At the end of the day Always shut off the fuel selector and run the fuel from the carb until the machine stops
Always store the machine with the fuel valve off as this leak could have been a major fire hazard by leaking a couple gallons of fuel on the garage floor.
If you will not be using the machine for a while add fuel stabilizer to the gas tank and be sure to turn off the fuel valve and run the machine until the engine stops.
If you have a similar problem be sure to clean the tank, install new fuel lines, and add an in-line fuel filter.

By the way the old carb is fine after I cleaned crud out of the needle valve seat.
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Old 02-23-2010, 06:43 PM   #4 (permalink)
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I am having the same problem with a Honda 450 s that i just purchased. The guy i bought it from had said it had been sitting for a while before he had sold it to me. We noticed that it had a small leak from the overflow but I figured with a good carb cleaning it would be fine. I have cleaned that carb numerous times and even ordered a carb kit online but nothing seems to stop the leak. Where did you purchase your in line fuel filter from and and fuel lines. Im hoping that this will fix my problem also.
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Old 02-23-2010, 07:37 PM   #5 (permalink)
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the problem may be that your float may be stuck or dirty. when my bike does this ( hardly ever but every bike ive owned has done it ) i just blow compresed air up teh hose and it will normally stop my leak.
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Old 02-24-2010, 06:31 PM   #6 (permalink)
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QUOTE (pepper23 @ Feb 23 2010, 03:43 PM)
Quote:
I am having the same problem with a Honda 450 s that i just purchased. The guy i bought it from had said it had been sitting for a while before he had sold it to me. We noticed that it had a small leak from the overflow but I figured with a good carb cleaning it would be fine. I have cleaned that carb numerous times and even ordered a carb kit online but nothing seems to stop the leak. Where did you purchase your in line fuel filter from and and fuel lines. Im hoping that this will fix my problem also.
any local auto parts store should be able to get you the fuel line and filter, **** even tractor supply carries small inline fuel filters, theyre probably in the lawn mower parts section. just take one of the hoses to make sure you get the right size.
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Old 02-24-2010, 06:33 PM   #7 (permalink)
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QUOTE (freakjeep93 @ Feb 23 2010, 04:37 PM)
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the problem may be that your float may be stuck or dirty. when my bike does this ( hardly ever but every bike ive owned has done it ) i just blow compresed air up teh hose and it will normally stop my leak.
compressed air can blow the needle clear out of the seat an thus change your float level, which means tearing the carb apart, putting the needle back on the float and resetting the float level.
learned that the hard way....
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97 Foreman 400 "the Froeman"
26" Bighorn 2.0
STI XM 40
4-2-4
Hi Lifter discs
Progressive 512's
Promark 2500 XT with Synth.
UNI filter
Pro Circuit T-4 slip on


03 Polaris Predator 500 "the Pred"
Holeshot XCT's
Pro Aluminum skids
K&N
Pure Polaris exhaust
Maier handguards

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Old 02-24-2010, 08:46 PM   #8 (permalink)
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oh..... it always works for me
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Old 05-16-2013, 12:37 PM   #9 (permalink)
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I know this thread is older, but I had to add my 2 cents. Dieselmudder is right, compressed air can unseat your valve and create unnecessary work. The easiest fix for this, and almost always successful, is to remove and reverse the inline check valve and gently blow air into the overflow line by mouth. Just a quick puff is probably enough to unseat any crud that accumulated over winter. Then turn the check valve around again and check for dripping. This literally takes 2 minutes, but the real solution is of course shutting off fuel and running the engine dry when you put it away.
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Old 05-16-2013, 09:23 PM   #10 (permalink)
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polish the float needle with an aluminum polish like mothers, and polish the brass needle sleeve with a Q-tip and some aluminum polish, they stick really easy.. Works every time
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