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post #1 of 6 (permalink) Old 01-29-2012, 03:59 PM Thread Starter
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Angry leak!

so i have a 1994 polaris xlt and i cant get it started and i noticed that i have gas leaking from where my exhaust manifold meets the engine block. does this just mean i need a exhaust gasket? if so where can i find them? and last but not least could this be the reason that i cant start my sled?

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post #2 of 6 (permalink) Old 01-29-2012, 04:08 PM
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u can buy just that gasket anywhere that has gasket kits even dealer isnt to bad not shure if that would b why its not starting what else is it doing little more info
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post #3 of 6 (permalink) Old 01-29-2012, 04:16 PM
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If you are leaking gas out the exhaust, you have flooded your engine pretty full of gas. I would pull the drain on the bottom of block and see if fuel drains out. Then you need to address the source of all this gas. Either your floats are shot, or misadjusted, allowing the carbs to overflow into the engine, or your needle and seats are shot. It could even be stuck or badly adjusted choke plungers letting gas by. This washes out the plugs, soaking them with fuel, so you cant start. Get the engine dried up, fix or adjust those carbs, and you should be good to go.

2000 Indy 500 XC, Fox shocks up front, M10 trail in back. '99 440 XCR for my son. 96 XCR 600 SP tripple pipe, 862 miles on it !! (until it snows....then look out, odometer !!)
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post #4 of 6 (permalink) Old 01-29-2012, 05:38 PM Thread Starter
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Ok i will pull the drains on the bottom of the block and get that all dried out. but how do i adjust the carbs? what is a web site where i can just get the exhaust gaskets?

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post #5 of 6 (permalink) Old 02-02-2012, 08:56 PM Thread Starter
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anybody know how i should adjust the carbs?

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post #6 of 6 (permalink) Old 02-02-2012, 09:14 PM
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Just because gas was leaking past the exhaust gaskets does not mean they are bad, I would get it running first and see if exhaust shoots past the junctions, then I would worry about new gaskets. For the carbs, pull each one, remove the needle and seat and check for pitting or a wear ring around the tips, if it can be polished with some steel wool, you may be able to reuse them for now, if it has a ridge you can feel, time to get new needle and seats. To adjust your float level, hold the carb upside down, and with a short hose hooked up to the fuel inlet, blow into it as you lightly push down on the float arm. At level or just before the arms are level, you should feel it shut off your breath tightly. Remember, we can only put out about 5 psi with our breath, a needle and seat needs to be good past that, so this is not an iron clad guarantee they seal good against fuel pressure, this just tells you your floats are in adjustment. Then check your choke plungers, with the choke off, you should have some play in the end by the carb, this shows the spring is fully extended and sealing the plunger in the hole.
There are tons of online information, google " 1994 Polaris xlt carb settings" and it should give you lots of info, probably even some Youtube videos of people rebuilding/adjusting their carbs.

2000 Indy 500 XC, Fox shocks up front, M10 trail in back. '99 440 XCR for my son. 96 XCR 600 SP tripple pipe, 862 miles on it !! (until it snows....then look out, odometer !!)
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