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04-05-2012, 01:04 PM
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Junior Member
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Member #24915
Join Date: Apr 2012
Location: Paola, KS
Posts: 10
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06 sportsman 500 carb
Im having trouble with my machine bogging down and dying when I give it any throttle. It will idle fine, and will run on about half choke if you give it gas. I have already checked and cleaned the fuel lines and fuel pump, put in fresh gas, and cleaned most of the carb. ( couldnt get the main jet out.) And it has a pretty new K&N air filter. I want to try a carb rebuild but cant seem to find a kit for the 06 sportsman 500 H.O. model. Will a kit for a different model or year work? Or Is there something else I should try to get my bike running. Also when I took apart the upper housing on the carb, the E-clip that goes on the needle jet was just sitting in there and the end of the needle looks like its been worn on something. I put it back how it looked on the schematic but it made no difference.
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04-05-2012, 07:23 PM
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Super Moderator
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Member #193
Join Date: Feb 2009
Location: Port Angeles WA
Posts: 15,491
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Welcome to the board! 
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04-06-2012, 12:53 PM
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Polaris ATV Legend
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Member #23274
Join Date: Feb 2012
Location: Reno,Nev.
Posts: 1,565
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The clip for the needle goes in the middle slot for starters. Also the main jet is the issue here.I don't know why it would be so hard to remove the jet.
__________________
'96 Xplorer 300 Aftermarket CDI box, K&N filter, jet kit, reworked expansion chamber from dirt bike, 1" taller + 1" wider rear tires, dual wenches, Rack on rear/w cargo pac, polaris box on front, Mossy Oak cover on seat, back-up lights on rear, aux. power source for GPS,"Theft deturent's", hand protectors, new clutch springs coming! Would love to find GURU style bumpers! By the way, I'm also a graduate of AMI with over 20 years of motorcycle mechanical experiance. New to quads, but the same basic engines. 2 stroke or 4 stroke!
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04-06-2012, 05:09 PM
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Polaris ATV Legend
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Member #11982
Join Date: Feb 2011
Location: Douglas Wyo
Posts: 3,068
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pilot jet plugged if it wont run without choke, jets can be removed with regular scre driver, need a real thin blade for pilot
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04-07-2012, 08:26 AM
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Junior Member
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Member #24915
Join Date: Apr 2012
Location: Paola, KS
Posts: 10
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Thanks for the suggestions.
I was able to get the pilot jet out and clean it with carb cleaner and air compressor, I tried unscrewing the main jet but it only turned about 1/8 turn and didn't feel like it would turn any more so I didn't force it. Does it come out thru the hole in the bottom of the carb where the screw cap is, or from the inside where the float is?
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04-07-2012, 05:08 PM
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Polaris ATV Legend
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Member #11982
Join Date: Feb 2011
Location: Douglas Wyo
Posts: 3,068
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have to take bowl off of carb, there is no way you removed pilot jet without taking bowl off, what did you remove? the pilot screw?
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04-08-2012, 10:34 PM
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Junior Member
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Member #24915
Join Date: Apr 2012
Location: Paola, KS
Posts: 10
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Im not sure what its called. On the bottom of the carb there is a bolt head, only about 1/4 inch tall and i think its 17 mm, if you unscrew it its just a cap or something, has a o-ring at the base of the threads. I dont know if its just to allow for easier access to clean out the carb or what. If i get a chance to work on it tomorrow Ill try to pull that main jet and clean it, maybe that will solve my problem.
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04-09-2012, 04:22 AM
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Polaris ATV Legend
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Member #11982
Join Date: Feb 2011
Location: Douglas Wyo
Posts: 3,068
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thats just a drain plug in bottom of bowl, ,need to remove airbox from carb and frame, slide carb back into holre where airbox was, turn carb upside down, remove 4 screws from bowl, remove bowl, remove all jets and spray them clean with carb cleaner and compresses air
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