Seth C. wrote on 04/07/09 at 13:33:02:darn I thought I had it covered. To make things simple, what is the best way to determine if it is a bad petcock or bad float valve? Thanks to all who have helped already.
Now that you have a new vac line installed on the petcock, at least you know if was dry when you put it on. To make it simple… disconnect the end of the vac line that connects to your carb. If it is wet with gas, your petcock is bad. Replace it. Get the same one or get the raptor that many people here seem to like.
If it is not wet than that is not the problem. The petcock has a diaphragm in it. When the engine is running the there is a vaccum created inside the hose that pulls on the diaphragm, opens a valve and allows fuel too flow through the petcock. If there is fuel in the vac line… the diaphragm is leaking. (see first paragraph).
If it is okay, the problem is probably with your float valve. Maybe it is not adjusted correctly or the float is filled with fluid. Sounds like the valve is not closing and gravity continues to pull fuel into the bowl and the extra fuel is overflowing into your air box. If this is the case you will most likely need to disassemble the bottom half of your carb and do some inspecting/tuning/fixing.
I suggest:
1. Buying yourself a clymers manual.
2.
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=11804372493.
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=11918999854. Fully understanding what your about to do/fix before you go about doing it and risking more damage.
Now this is all new to me as well but the guys on this forum are great. I am sure they will correct me if anything above is incorrect.