johnmc408

Thanks everyone for the feedback. That AJP 3.5 'Ultrapassar' looks fun, but of course California doesn't allow it ;-(

Thanks! I don't have the vacuum stuff at the moment, but I did find: The bottom tank was full (I could see the gas). If the manual is correct, it is .70 gallons in there. The top tank also had some gas, so I removed it and poured it into a can. Maybe 1 gallon (might have messed up my counting ;-) So, tons of gas, why did the light turn on... Since you mentioned vacuum, does the top tank drain into the lower tank because of vacuum? If so, I might have idea. The bottom fuel tank cap has a brass hose attachment to connect the "fuel tank air hose" 7 9435010512 ALUMINIUM FUEL TANK CAP 1 That brass hose attachment swivels freely and can be removed. It is NOT air tight. I assumed that gravity moved the gas between tanks, but I don't know. The parts_diagram just shows 1 piece for the "aluminum fuel tank cap" and doesn't show the brass hose attachment... What does yours look like? What do you think? I'll take a picture tomorrow. Plus, if the bottom tank was always full, why would the low gas light come on? It is possible that I rode ~5 miles on the bottom tank, the light came on and then blowing into the top tank started to push gas to the bottom tank. After that, the low gas light did seem to not be as bright, but after it came on the first time, I was sure I was going to be a long walk from home, so might not remember correctly ;-) Strange things... ps (and a few more questions) I am in San Jose, Calif. Do you know if I can take off the "stuff" that need the software update and just send it to the shop? Or, do you have to hook it up and do the settings while it is running? And finally, is there any manual idle adjustment that might be "good enough" until I get the software done? Just want something to get by...

This is probably like asking everyone about their opinion on oil, but what the heck ;-) I like my Explorer, but I have 2 concerns: 1) It might just be too complicated with my limited mechanical skills (and limited dealer support). See my post on fuel issues, engine mapping, etc. If it breaks I have to learn how to fix it and that won't be happening on the trail. 2) The official riding areas in my area are setup for dirt bikes, so a trials bike is mostly overkill. It has helped me on a few trouble spots that I can now ride on my dirt bike on, so I am very happy about that. These spots are usually scattered around the park, so not ideal. I am sure there are many expert riders in my area that know difficult/secret spots, but I am not that good ;-) I certainly have read up on the Freeride and the x-trainer. I even wonder if I lowered a 125/150 how that would be. If I sold my Explorer, I am leaning towards the x-trainer. The Freeride does seem closest, but I am concerned about it. Lots of people sell them after just a few hundred miles. I also see KTM, and probably others, releasing new 125/150s that are really light. I wonder if the Freeride will still be offered with these new bikes coming out. I think I would rather have a lowered 150 than a Freeride. Unfortunately, I haven't ridden any of the bikes that I mentioned. What I think I want is: low speed maneuverability, ability to loft the front wheel from a stop, low seat height and light weight. (Yes I know you can't have it all, so looking for next best ;-) Everything is a compromise... I currently have a KTM 350 4 stroke which I really like. It is pretty heavy and tall for me (30 inch inseam). It also is hard to maneuver slow as the idle want to keep the bike moving. I don't plan on ever selling this bike ;-) I just want a 2 stroke that I can take on difficult trails w/o expending as much energy and effort as on the big bike. I don't need to go fast. Last weekend I went on a crazy rocky Jeep trail (for a short while anyway) and it was perfect for the Explorer. But I would never take my KTM on it. Way too tall, way too heavy. I needed to bounce around, over, between boulders... Thanks! for any opinions ;-)

I have posted before about the tanks and I think I have them connected correct and with safety wire on the tubes between tanks. I filled the tanks slowly, bounced the bike around etc. On the trail, after about 5 miles, the low gas light comes on. I figure I better head back (slowly). It did seem to run out of gas and I would lean left/right and I even blew into the top tank to try and push gas lower. I was able to keep riding and made it back. I think the top tank is the bigger of the two...shouldn't that go more than 5 miles? Some complications: I was at maybe 6000 feet and the bike didn't run great. I don't think there is an idle adjustment. I doubt it has updated software. I didn't do it as Lewisport is too difficult to get to and the guy I bought it from wasn't technical... All that said, the tanks should be mechanical. And I think the tanks should get ?50? miles (read this somewhere). My thought is to drain the gas and try and put in 2.2 gallons. If I can't get in at least 2 gallons, something must be wrong. What is the best way to drain the tanks? Thanks!

Thanks! I'll give these a shot.

Has anyone found a way to lighten the clutch pull? Different fluid? My Explorer is currently harder than these bikes I have tried: Sherco 290, GasGas 280, KTM 350... It is not problem with 2-3 fingers, but 1 finger is too tough... Thanks!

Thanks, what about removing the "clutch hose"? That might make it easier to get some leverage in the top left corner... If I do that, do I need to bleed anything? I didn't see a torque value for this bolt. I don't want to break anything else ;-) Thanks!

2002 TXT Pro 280 The brass bushing came stripped and I tried a screw remover, but it just seemed to chew away the brass (not a mechanic ;-) Any idea? I just might have to replace the whole water pump...probably needs it, but would like to see inside and save some $$. I am sure it has been years since the water pump was removed, do I just 'jiggle' it back'n'forth? I can get it a bit loose, but won't pop out. Tried some needle nose pliers on the bottom and rock the WP holding the top tube...might be working, but not quickly... Thanks!

I know this is a bit old ;-) I have searched and couldn't find any references to this technique. I am curious if it is possible...not sure I would do it, but curious... My 2002 sherco has the lightest clutch I have ever used. I wouldn't mind my Explorer to be the same though ;-)

It tore when removing it...I super-glued it, seems to be (barely) holding...but wondering if there are any replacements to get... Thanks

For me, looks like green & green/black for the wires that connect to the tank. The connector with the light bulb attached, could be any color, and mine is blue/black.

Oh, and on the TPS, I haven't set it. I do notice that I can't just crank the throttle in neutral and get it to always rev. I know there is something a bit off. So far in riding, I haven't had a problem though. It does need to fully warm up. I do need to get it out to lewisport at some point...

Thanks! I'll take a look at the wires and sensor. My first thought was that the tanks were not connected, so I disconnected the breather tube on the top tank and then lifted the tank up, that caused gas to rise out of the lower breather tube, so I think it might help with air as well. So far, I can't really ride long enough to run out of gas ;-) I do have a regular dirt bike and would ride that for anything where I can go faster or longer distance. Right now I am targeting smaller sections of OHVs that have difficult parts. I do want to find better trails. (Not really into trials _competitions_, so only did that once). BTW, there are supposed to be 1 or 2 Explorer riders in NorCal...Have you heard of anyone named Alan Ande[sa]? I can't read the last 2 letters...The phone number I have from him is old. He was supposed to do more "adventure" trials riding...

Me again ;-) Sorry for all of the questions! The gas light is always on, but the tank is full...and I have gone through more gas than is just in the lower tank (2L I heard) and I haven't run out. Any ideas? BTW, the other lights work for blinkers and lights, so I don't think the bulb swapped position. I think there are only 3 bulbs (nothing in top right). I do see that there is a sensor in the bottom tank and appears to be connected to the correct light (green/black wire if I remember). Thanks!

Thanks! I'll give that a shot. If you get the "pop-pin" working, let me know. Also, did I read somewhere that you have a different gas cap with a 1-way valve? I think that would be a nice addition if I can find the right size...

So I was looking at this nut and noticed that is was turning easy...so at that point I just decided to replace the pedal as it needed to be tightened anyway. And, since my kickstand fell off the last time I rode the bike, using the screwdriver technique worked easy. Test ride tomorrow to see if everything works. BTW, any trick for aligning up the fuel tank (long) bolt? I just can't get it to screw in. I do have the 2nd air filter (as I have the 2012 model and don't want to remove the filter ever again ;-) I lift the tank and it looks lined up, but it never takes... Thanks!

Thanks, I plan on giving it a go....might wait until after the weekend, to make sure I don't mess something up and then can't ride...

Thanks! Definitely keep in touch. If you head down this way we can meet up for a ride!

Thanks, it might have come that way, but I couldn't remember. I used some safety wire on the lower hose, so hopefully this will stop the leaks!

I found a video of a german guy that had the parts to swap from Explorer to Trials and video'd it. It really looks like the tanks are connected at the top, with what I thought were vent tubes. I am going to try that out unless somebody lets me know better. Thanks!

Reading and thinking more about this. The gas cap (and rubber insert) both have a pin hole in them...so maybe *that* is the gas vent and I need to connect the bottom tank metal nipple to the top tank "vent" hose together... Maybe I am thinking this all wrong...who knows ;-)

I have looked at the manual, but the description and pictures aren't enough for me to really understand. Is the hose that extends from the front of the "top tank" a vent hose? From the manual, this looks to be yes. I have a hose extending out and it looks correct to me. On the bottom tank, there is a metal "nipple" (near the top) that rotates 360 degrees and when the tanks are full, does leak gas out of it. The nipple looks like it would have a hose attached to it, but there is none currently. How should this be setup? Do I just point the nipple up/front and deal with the gas that sloshes out? Or, if this is a vent, should it also have a hose? I can try and take a picture if that helps. Thanks!

Ahhh, good to know. I'll give it a look and figure out the socket trick. Thanks!