Bayou 300 carb problems

[shadowdog5]

Thanks for the reply Greg, I'm going to buy one anyway no sense letting my quad sit when I could be having some fun...

[99Bayou]

Hello all,
Same story different poster. I've got a 99 300 Bayou and it leaks gas out of the carb overflow, and won't stay running unless it's fully choked at an idle. Any throttle or no choke is an instant stall. I'm getting ready to try the carb on ebay that's been recommended. I found this thread on a google search and the seller actually has it linked as well as a testimonial of sorts. Thanks for all of the info I've gained from reading everyone else's troubles.

[lutherfetch]

I am glad I found this thread. I have rebuilt my original carb a number of times and thought I was doing something wrong. Clearly the problem is the carb.


I did an engine rebuild and replaced the original carb with the ebay replacement others have written about. My Bayou is running decently, but this is not a "drop in replacement" as advertised. Also, the vendor has not returned my emails. So, I am not particularly happy with them at the moment.

First off, the carb fits well against the intake manifold. It does not fit the air intake side no matter how much ramming, cramming, and cursing you do. So, I modified the intake by using a 2" rubber plumbing joint from the hardare store. After some modificattion of the original hose, some black RTV, and a lot of cursing, I got a pretty good fit. I stuck the smaller vaccuum tube inside the old one and glued them together with RTV. Also, I had to pull apart the throttle control (thumb) and adjust the length of pull.

Another post mentioned having a problem with the choke cable. Not sure why. Mine was an original cable and it works fine. I did have to drill out the throttle hole a bit to get the throttle cable to work properly. I REALLY like the primer function on the bottom of the carb. I think this will be a big plus in the winter.

I live at 8000 ft, so I moved the needle DOWN by moving the clip UP on the main jet needle. I put it on the top setting, and by doing so, I think I have gone from too rich to too lean. Will drop it one more (2nd from top). This should give me back some power.

With about an hour of tweaking after the install, I have a running ATV. This carb does seem to work, but it is not a "drop in replacement". You need to have a good working knowledge of how a carb works and a willingness to make some modifications. You can expect the replacement to take most of a day. Be sure to pick up a 2" rubber coupler from the local hardware store and a tube of black RTV before you start.

Email me if you have any questions. I am not an "expert"... but I did get this thing to work.

john