2003 Honda XR100 Spewing Gas - Ideas?

Rider 5280
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Denver Metro, CO, USA
Edited Date/Time 8/28/2023 11:31pm

I just bought kiddo an old 2003 Honda XR100.

Previous owner said he fixed the carb, it seemed to run ok for about 30 minutes, but always had a hanging rev after cracking the throttle. Now at about 30 minutes of run time it is spewing fuel out of the overflow tube.

So ... for you guys who have been there and fixed this on XR100s, what was the fix?

To me, it seems like a faulty float, but I am speculating. I haven't opened anything up yet.

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Factor E
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So Cal, CA, USA
8/28/2023 11:11pm

Float is sticking   Try tapping side of carb bowl to free it up

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Rider 5280
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8/28/2023 11:30pm

Thoughts on permanent fix? Did the previous owner bend or damage something trying to fix it do you think?

Factor E
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8/28/2023 11:48pm Edited Date/Time 8/28/2023 11:49pm

Pull the bowl off an check needle and seat   Look for no wear ring on the rubber on needle  make sure seat is smooth on the inside check float level height

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Toby259
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Rockford, MI, USA
8/30/2023 10:56am Edited Date/Time 8/30/2023 10:57am

I recently had a similar issue on my 06 KLX125, same carb similar bike I bought used.

typically the float adjustment doesn't just change by itself, I would say 90% chance its either the float needle tip or seat O-ring.

I found contamination particles were getting stuck in the float needle, come to find out the little screen filter in the fuel shutoff valve (petcock) had deteriorated and small particles were getting in the carb and stopping the float needle from sealing. I bought a carb rebuild kit on Amazon, I think it was Moose racing or something, but it was all Chinese parts.  I ended up cleaning the cone-shaped tip of the original needle, it had a small crusty ring around it from old fuel or ethanol (for this reason I only use Rec gas).  I used the seat O-ring from the kit and some gaskets and it fixed the issue.  I also added a small fuel filter between the petcock and carb to eliminate contamination.

also pay close attention to the assembly of the plastic float - it's possible to install it upside-down!   I almost did this the first time.

2

The Shop

Rider 5280
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Denver Metro, CO, USA
8/30/2023 11:35am

Awesome feedback - thanks guys!

seekborrow
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Anchorage, AK, USA
10/8/2023 4:33am
Factor E wrote:
Pull the bowl off an check needle and seat   Look for no wear ring on the rubber on needle  make sure seat is smooth on...

Pull the bowl off an check needle and seat   Look for no wear ring on the rubber on needle  make sure seat is smooth on the inside check float level height

@geometry dash world Ended up polishing the cone-shaped tip of the original needle. Also utilized the seat O-ring from the kit and several gaskets. I hope it is useful to you. 

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