Gas In Air Box?? Tech Challenge

1.) float level check.

2.) TPS settings correct

3.)Clutching and gas mpg go hand in hand, if the clutchs are lazy to some extent it still can perform by getting up to peak rpm but may not backshift as well and it will take more throttle to maintain the same mph as when the springs, and bushings, buttons were new and not increasing the friction. I would definitely have a gander at the secondary buttons, the clutch springs and the clutch pucks in the primry, these parts do definitely wear and with 10,000 miles on it the clutch springs will be getting tired. No other part works harder then the clutch springs, the amount of cycles they see in a single ride is amazing.
 

thanks Mr Viper....I will be tearing into the clutches tommorrow. After the kids rip into the gifts I will need something to pass the time. As for the TPS Settings when I did a check they seemed to be in spec. at idle as per the manual. Is there anything else I should be checking. with the TPS.

Floats are spec. I will be setting them closer to the lower end
 
By the way....I will be changine the Primary spring....is there something recommend other than what comes stock....I am an aggressive trail rider.
 
Check the weights and rollers for wear, the weights may have a flat spot in them or the rollers can be out of round. Replace all the bushings and check for a wesk primary spring.

Not much to do in the secondary but replace the plastic cam buttons. There are 3 of them. Check the secondary spring for wear. Check the helix ramps for excessive wear.
 
Ok now I am getting really heated!!!!!!!!!. I have done everything I can about this fuel consumption thing. I need some more suggestions please. Cleaned up the clutches and they are working mint. Set the floats they were already in speck. My buddy just picked up an 02 Viper and we were out riding and I was using twice the fuel as he was. I need some more suggestions short of me burning this thing and getting a 4 stroke. Man I am heated.

Is there any way that my timing could be off as the crank may be out of sinc. Is there any way to check timing on these things. Keep in mind I have switched out the CDI with no improvements.


Help anyone!!!!
 
if the crank was out of sync you would feel vibrations. compared to you're buddies sled. i thought i heard this before but the fuel pump could be malfunctioning.
 
pull the pulse line of the fuel pump see if there is any fuel getting threw the diaphram but when this happens the sled would usually run bad just a thought
 
hey boys thanks.....i have already been thru the pulse line.....it is providing good suction.....i have not changed out the fuel pump yet nor have I been able to switch out my carb rack. Once I do that I am all out of options.


there is no vibration the sled seems to be running good...pulls hard for 90 miles per tank then I need gas...... I don't smell any fuel either so it can't be a leak.

if it was the fuel pump don't they tend to restrict fuel instead of send to much when the malfunction.


Any more suggestions would be great......
 
no it wont restrict fuel if the diaphram has a tear it will allow fuel down the line into the base and it would cause a rich condition
 
no I don't think so but here are some more symptoms though.

I raised the needle by .5 and changed out the main jet to a 152.5. plug color shows that it is definetly burning leaning I am just not sure if it is only on the high end.

there is a definete babble.....very defined...when I am driving in mid-range.....what other seats are there other than the float needles
 
I Found the Problem...Now Help Me Fix It Please

Well I found the problem.....Yesssssssssssssss....Now I just have to figure out how to fix it.

I took the airbox off this morning and have done so in the past but I never reved the motor up over 6000 rpm. There was never much spray below 6000 so I didn't think I had a blow back problem until I saw so much fuel in my airbox.

Today I put her up on the stand and gave it some good throttle. As the sled went over 6000 rpm the spray came out quite heavily from of all three carbs.
It was so heavy that there is no doubt about it......this is my problem. I know there is some blow back to be expected but not this much!!!!!

Trouble is what the heck is causing this. I have changed the reeds they are brand new. When I changed them all the reeds were seated to the cage so how the heck is gas blowing back thru the carbs. The reeds are supposed to prevent this from happening so how is this occurring other than the reeds staying open.

Some suggestions please. Should I change out the whole reed cages with new reeds or what??? I think I am going to do that anyway but I don't see how new cages are going to do anything.

Is there any other reason this could be happening because my reeds are brand new. Could the cages be messed up and out of spec or what???

It can't be the fuel pump or I would have other issues when trying to start the machine. Anyway it has been 3 years and lots of $$$ trying to figure out what the problem is. Now I can see what it is without having to jump on the machine and drive 50k to see what the fuel consumption is. I just have to throw it up on the stand and hog on the throttle and watch for the huge amounts of spray!!!!!!! Once I have reduced that the problem will be fixed.
 
Ya I am going to check on the vent lines cause it is sucking more fuel than it needs to be....so something must be plugged. I took the reeds out and they look good everything seems to be fine. Something must be plugged and its not the airbox cause I am getting that excessive blow back when I hit the throttle and then it seems to even out after that. The carbs are all coming apart tonight.......again!!!!!

Do you think that my pipe or can could be plugged up a bit causing extra back pressure and thus this extra blow back????
 
I heard of critters making a home in the exhaust over summertime and will cause the sled to not run right but dont have a clue if it will cause excessive fuel consumption.

Best thing to do if its not your vent lines is to fumbe around with the silencer and see if they made their way up there into possibly the pipe. All depends how and where the sled was stored. I would check the vent lines first.
 
Well thats not a valid test, when you take the vent lines out of the airbox it goes rich, so to make that valid you would have to do that test with like 145's in it and see what it does on the jackstand. Are you running the vent lines in the airbox normally?

Are your P Valves opening? That whole 10,000mi. thing, did it always eat this much fuel? You said you checked the fuel pump pulse line, the pump could lose a diaphram and push fuel through the pulse line into the motor, take the pulse line off the pump, slightly pressurize the fuel tank and see if anything comes out of the pulse fitting, if so, you have a leaky diaphram.

Getting back to the vent lines, all these sleds have spit back into the box, noticably the Vipers seem to be messier than SRX's, I run srx carbs on my Viper and don't seem to get the mess you see on most Vipers.

Where are you running this thing, you said you drive it with 152.5's? In the cold? Around here, and we have good air, that thing wouldn't make it across the lake on 152.5's, unless you pulled the vents out of the airbox.

Someone mentioned a plugged exhaust, that would be possible especially because of the miles. I've had several much older sleds have problems with mufflers falling apart and plugging up, if you lean out your sled and do your jackstand test and still get alot of high end spit back, try a different silencer and see if it changes. Does it seem to be down on power?
 
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