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Discussion Starter #1
I have a 1997 Xplorer 300. I went to crank it this evening and during the normal cold-nature starting process, I look down and there is a fluid coming out of the top of the recoil starer. I assumed water at first, until further inspection. It was fuel/oil! What could cause this? PLEASE HELP!
 

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gonna guess that the seal (#3) is bad, allowing the fluid into the recoil housing


# Add Part# Description Quantity
- 1341146 GEARCASE ASM,PRD. (Incl. 1-49) 1 Usage
1 3233002 CASE, LH 1 Usage
2 3233026 SCREW 10 Usage
3 3233248 SEAL 3 Usage
3 3233248 SEAL 3 Usage
4 3233024 BUSHING,PIVOT 2 Usage
4 3233024 BUSHING,PIVOT 2 Usage
5 3233025 STUD 1 Usage
6 3233021 PIPE, KNOCK 2 Usage
6 3233021 PIPE, KNOCK 2 Usage
7 3233022 SHIFTRAIL,LOW 1 Usage
8 3233023 SHIFTRAIL,HIGH/REV. 1 Usage
9 3233038 SHAFT,LOW SHIFT 1 Usage
10 3233044 O-RING Substituted by 3233548 2 Usage
10 3233044 O-RING Substituted by 3233548 2 Usage
11 3233040 WASHER 2 Usage
11 3233040 WASHER 2 Usage
12 3233045 RING,RETAINING 2 Usage
12 3233045 RING,RETAINING 2 Usage
13 3233153 BELLCRANK 2 Usage
13 3233153 BELLCRANK 2 Usage
14 3233054 WASHER 2 Usage
14 3233054 WASHER 2 Usage
15 3233055 NUT 2 Usage
15 3233055 NUT 2 Usage
16 3233039 SHAFT,HI/REV,SHIFT 1 Usage
17 3233031 PIN 2 Usage
17 3233031 PIN 2 Usage
18 3233030 BRACKET 1 Usage
19 3233032 SPRING 1 Usage
20 3233018 BEARING 3 Usage
20 3233018 BEARING 3 Usage
20 3233018 BEARING 3 Usage
21 3233033 SCREW Substituted by 3233747 4 Usage
21 3233033 SCREW Substituted by 3233747 4 Usage
22 3233122 SHAFT, INPUT 1 Usage
23 3233019 BEARING 1 Usage
24 3233007 WASHER 2 Usage
25 3233125 GEAR, 33T 1 Usage
26 3233009 BEARING,NEEDLE 1 Usage
27 3233010 WASHER 2 Usage
27 3233010 WASHER 2 Usage
28 3233126 DOG,ENGAGEMENT,LOW 1 Usage
29 3233175 SHAFT,REVERSE 1 Usage
30 3233012 WASHER 2 Usage
30 3233012 WASHER 2 Usage
31 3233127 SPROCKET, 24T 1 Usage
32 3233036 CHAIN,SILENT,34P (11W) 1 Usage
33 3233014 BEARING,NEEDLE 1 Usage
34 3233029 RING,RETAINING 1 Usage
35 3233128 DOG,ENGAGEMENT,HI/REV. 1 Usage
36 3233129 GEAR, 25T 1 Usage
37 3233017 BEARING,NEEDLE 1 Usage
38 3233176 WASHER 1 Usage
39 3233177 RING,RETAINING 1 Usage
40 3233037 VENT 1 Usage
41 3233115 DIPSTICK Substituted by 3233478 1 Usage
42 3233448 PLUG 1 Usage
43 3233035 WASHER 1 Usage
44 3233003 CASE, RH 1 Usage
45 3233043 DEFLECTOR,OIL 1 Usage
46 3233020 BEARING 2 Usage
46 3233020 BEARING 2 Usage
47 3233123 SHAFT,OUTPUT 1 Usage
48 3233130 GEAR, 65T 1 Usage
49 5020741 BUSHING,SPEEDO.DRIVE 1


and if your also getting fuel in there, you should have a vent line running from the carb to the gearcase, and it should have a one way check valve, but on something this old there is a good chance that is not there or bad
 

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Discussion Starter #3
Here is a little history on the ATV. I purchased it very cheap. It had been used and abused. When I got the it, the throttle cable going to the oil pump was cut. It was covered in grease and mud. The carb was gunked up. All of the hoses were cracking. Some where even missing.

Here are some things that I did to the it last week. I removed the oil pump and put in a block off kit. I ran all new hoses. I cleaned the carb. I drained the crankcase, put in fresh oil. Drained all the water out of the the recoil starter, from washing it. I greased all the fittings and lubed the chain.

Now, there is a hose fitting on the bottom of the carb, that had nothing attached to it, when I got the atv. I assumed this was a vent line and just ran it north and zip tied it off, safely away from everything. Could this be the hose that should be attached to the crankcase, that you are refering to?

I also assumed that it was the seal, that would put the fuel mix into the recoil starter, however...what would cause pure fuel to pool up in the bottom of the motor like this? It is possible the carb needs to be rebuilt? A bad float?

I am also having difficulty starting. It will start and run great, but it is difficult to start, especially with it being so cold outside.
 

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if the carb is leaking fuel then i would first get it pressure checked, but very possibly you need a new needle valve. after time they decay and once they do, the carb will dump fuel out.

that hose very could be the hose that is supposed to attach somewhere to the crankcase. i dont know but im wonder or almost thinking if that hose is more then just a vent hose, if it is some type of pressure or vacuum hose and thats why it was attached to the crankcase. the fiche doesnt show where the hose attaches, but if memory service me right, i think those 2strokes did have a hose that went from the carb to the crankcase
 

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Discussion Starter #5
blueline15, first of all, I would like to thank you for the replies. Second, the diagram above is for the gearcase, not the crankcase.

As far as the hose goes, I don't know what to do. I am just as unsure as you are. With the carb, I guess I should just go ahead and rebuild it.
 

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wow, yeah i just realized that i posted the gearcase, wrong fiche...
at this point this is the limitation of my tech knowledge, only being a parts guy (and hopefully a little better one then this thread shows) my diagnosising and rebuild knowledge ends...i can get you all the fiche images you need though! i would try calling a few dealers to talk with their service manager. they should spend some time on the phone with you going over all the different things it could be. if they say "bring it in, we'll take a look" then call a different one. a good service manual would go throught all the common things it could be and why. hope that helps

number #28 should be the seal for the recoil i believe

# Add Part# Description Quantity
1 3085097 HEAD, CYLINDER 1 Usage
2 3083930 FIN DAMPER #2 2 Usage
3 3082910 NUT-FLANGE(10) 6 Usage
4 3084799 FIN DAMPER B 5 Usage
4 3084799 FIN DAMPER B 5 Usage
4 3084799 FIN DAMPER B 5 Usage
5 3084798 FIN DAMPER A 1 Usage
6 3085098 GASKET, HEAD (Head) 1 Usage
7 3080283 STUD 4 Usage
8 3084292 O-RING 1 Usage
9 3085013 ADAPTER, CARB. * (Incl. 8) 1 Usage
10 3081330 BOLT, ALLEN (Socket Head) 2 Usage
11 3081497 SCREW,(10) (Pan Head) 1 Usage
12 3082257 BAND-CARB MTG. (Incl. 11) 1 Usage
13 3082162 SEAL,OIL 1 Usage
14 3080103 PIN, DOWEL Substituted by 3086838 4 Usage
14 3080103 PIN, DOWEL Substituted by 3086838 4 Usage
15 3084801 GROMMET 1 Usage
16 3084800 BRACKET,WIRE 1 Usage
17 3084802 BOLT&WASHER ASM.(10) 2 Usage
18 3084791 CRANKCASE ASM. (Incl. 13, 14, 21-26, 28, 29) 1 Usage
18 3084791 CRANKCASE ASM. (Incl. 13, 14, 21-26, 28, 29) 1 Usage
19 3084018 GASKET, STARTER Substituted by 3085283 1 Usage
20 3082758 GASKET, ALUM,(10) Substituted by 7555998 2 Usage
20 3082758 GASKET, ALUM,(10) Substituted by 7555998 2 Usage
21 3083767 PLUG, DRAIN 2 Usage
21 3083767 PLUG, DRAIN 2 Usage
22 3084775 BEARING, BALL 1 Usage
23 3084792 SPACER 1 Usage
24 3084121 BEARING, BALL 1 Usage
25 3080739 BOLT W/WASHER 3 Usage
26 3083615 BOLT&WASHER ASSY. 2 Usage
27 3081635 SCREW&WASHER ASM. 4 Usage
28 3084581 SEAL, OIL, PTO (PTO) 1 Usage
29 3084119 STUD 4 Usage
29 3084119 STUD 4 Usage
30 3084795 GASKET,CYL,NA 1 Usage
31 3082911 NUT-FLANGE(10) 4 Usage
32 3083929 FIN DAMPER #1 1 Usage
33 3084793 CYLINDER (Incl. 7, 34, 38) 1 Usage
34 3085326 STUD,(10) 2 Usage
35 3084439 GASKET,EXHAUST,NA(10) Substituted by 3086757 1 Usage
36 3080530 WASHER LOCK ,(10) 2 Usage
37 3080285 NUT(10) 2 Usage
38 3084794 STUD



here this is the crankcase...
 
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