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Message started by oceantransistor on 11/25/21 at 18:01:05

Title: Airbox Fuel Leak
Post by oceantransistor on 11/25/21 at 18:01:05

Hello,

I've seen this topic raised before but need some confirmation so I'll start at the beginning. I'd like to make aware that I replaced the stock petcock with a raptor per this site's recommendation and have had no issue with the raptor for years. Just to eliminate the petcock as a potential cause for fuel leaks.

The 2003 bike was stalling so I thought it was time to do my first carburetor rebuild and spark plug change. Spark plug was black and the carb looked ok but I went ahead and rebuilt it since I've never done it before.

I made sure the float worked properly, cleaned the full body, replaced all the brass and rubber components that could be replaced and the float needle assembly. As a surprise to me the replacement main jet washer was metal and not plastic this time. Could that be an issue?

I changed the oil and took it for a short spin in which case it seemed to be running well but I noticed fuel dripping out via the carb bowl gasket. Luckily I was able to tighten it without removing the carb. Then after another test run I noticed fuel leaking out of the airbox with a hint of oil. Upon draining it the box was full of gas and the air filter was soaked.

Through the forum I read it could be a bad float or needle which I assumed it couldn't be since I took special care to rebuild and test. The only side note is that the rebuild main yet supplied had a smaller diameter hole than the 150 jet so I saw on youtube you could just use a drill to widen the diameter to 150 so I did. I doubt this could be an issue?

I've also read here that it could be too much oil which I did have well above the top line. I went ahead and gave the oil the sniff test and it didn't smell like gasoline so I drained enough to get it below the top limit line on the little oil window.

I drained and cleaned the airbox, removed the fuel soaked air filter and the seat to turn the bike on and keep an eye for fuel leaks. Ran it on idle and throttled a little for about 30 minutes and didn't see any leaks.

My concern before moving on to the brakes is, can I let the air filter dry and reuse it since it's new or should I just replace it? Is it likely the fuel leak into the airbox was from too much oil in the engine?

I guess my next move is to put it all back together and ride it around a bit to make sure it doesn't leak so I can move on to the brakes.

I'm in SoCal and my favorite time to ride around is winter season in the afternoon. Trying my best to get the bike safely back on the road while the weather is good. I look forward to your replies.

Title: Re: Airbox Fuel Leak
Post by verslagen1 on 11/25/21 at 21:50:34

797573777862647778657F65627964160 wrote:

Hello,
I changed the oil and took it for a short spin in which case it seemed to be running well but I noticed fuel dripping out via the carb bowl gasket. Luckily I was able to tighten it without removing the carb. Then after another test run I noticed fuel leaking out of the airbox with a hint of oil. Upon draining it the box was full of gas and the air filter was soaked.

This seems to be the problem, if the float level was correct, it won't leak from the bowl.
check your float level.

Title: Re: Airbox Fuel Leak
Post by Dave on 11/26/21 at 05:06:46

I worked on a Savage for a member a while back....and it left running great. A few moths later the owner commented the bike would sometimes not start, and occasionally fuel would leak from the bike....it had a Raptor petcock.

When I got the bike back I took the carb apart and found the float had some fuel inside one of the brass chambers. It felt fine - but when I shook the float I could hear the liquid sloshing around inside.

So........I would suggest you check your fuel level and/or float. If your carb has the drain screw and nipple on the bottom, you can connect a clear tube and check the fuel level without taking the carb apart.....the level of the fuel should be just below the gasket level of the float chamber on the bottom of the carb.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1367212825

Title: Re: Airbox Fuel Leak
Post by marioivargas on 11/26/21 at 08:58:35

When I rebuilt the carb I did the leak test on the float under water and saw no bubbles coming and heard no rattles when shaking it. It did have a small dent but it didn't seem to affect its performance.

I do have a drain screw and it even seems to have what appear to be an overflow valve? I'll try the level test with the fuel hose as soon as I can get a little rubber hose. Perhaps my float tabs need to be adjusted.

Title: Re: Airbox Fuel Leak
Post by ohiomoto on 11/27/21 at 04:56:29

Where did you get the parts you used to "rebuild" your carb?

You may have replaced the float needle and seat with the wrong parts, installed them wrong, or simply need to adjust for minor variations like the float level as stated above.

Also, you stated you drilled out the main jet. That's not recommended. Furthermore, most bikes don't need more than a 150 mian. Who knows what you have it there now.

Did you replace the needle jet too? Was it match to stock needle?

Other that the slide, carbs really don't "wear out" or need to be "rebuilt". They mostly just need to be cleaned and tuned. I never just replace parts for no reason.

"Don't fix what isn't broke." This rebuild may have created more problems than it solved.

"When in doubt, go stock." These bikes will always run acceptably in stock form. If you get into a pinch, go back to stock and then solve the problem causing the issue. You can go back and tune it later if desired.

Title: Re: Airbox Fuel Leak
Post by marioivargas on 11/27/21 at 13:46:32

Thanks for the tips. This is the kit I bought.

https://www.ebay.com/itm/232519004595

It's by Sumo and I used all the parts available. I'm fairly novice so I though replacing all the parts would be best to have it run optimal. Probably just needed cleaning and a new spark plug in hindsight.

At the moment since I didn't find any fuel leaks after draining some oil and retesting I moved on to working on the front brakes.

I changed the disk and started rebuilding the front caliper but the gunk in the outer seal groove is so bad I can't get it cleaned enough to properly seat a new seal properly. I tried to force the piston in but it just shredded the new outer seal. I'm just going to buy a new caliper to make sure I have a healthy brake system.

I'm going to test the the carb float with a rubber hose attached to the fuel drain plug as recommended before making any further adjustments.

I'll keep you all updated.

Title: Re: Airbox Fuel Leak
Post by marioivargas on 11/28/21 at 15:35:07

I did the float test. Float seems to be working properly. Gas level maintained well under the bowl gasket level.

It was likely too much pressure pushing fuel back from too much oil as I did see what looked like a hint of oil in the airbox fuel when I drained it. (Oil is now drained down below top line level.)

I will keep an eye on this and do more interval tests for a while to make sure.

Just waiting for a new caliper and new grips to mount on the bike to get it back on the road for some light cruising. I'm not brave enough to cruise without the caliper.

Cheers all, stay safe and humble!

Title: Re: Airbox Fuel Leak
Post by marioivargas on 01/30/22 at 17:23:53

Just an update. The bike has been running great with no further fuel in air box issues.

Unfortunately someone decided to break into my battery box last night and steal the battery so a new project now will be replacing the positive battery cable, the box, a battery and seeing how I can make it more secure from theft. I might start another thread on that to see if I can get some ideas though I hear it's very uncommon seeing how these batteries are cheap.