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Old 12-17-2010, 11:04 AM
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2004 sportsman 700 carb problems

I bought a 2004 sportsman 700 project and have had a rough time with it. I am getting close to getting it together and am having troubles with the carburetor. It had a hesitation in it and rough idle so decided to rebuild. After I rebuilt it, it will only run with the choke pulled out. Once it is pushed in, it dies completely. What could be wrong? I replaced everything except the diaphagm assembly. Could that be the problem.
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Old 12-17-2010, 11:35 AM
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sounds like your pilot jet needs to be turned out a bit. did you by any chance screw it in all the way when you replaced it and forgot to turn it out?
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Old 12-19-2010, 04:40 AM
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Check the carb boot between the carb and head. They are very prone to cracking.
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Old 12-19-2010, 05:09 AM
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Quote:
Originally Posted by cookies View Post
sounds like your pilot jet needs to be turned out a bit. did you by any chance screw it in all the way when you replaced it and forgot to turn it out?

Which jet are you referring to? when you look at a schematic, there is 2 pilot jets.
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Old 12-19-2010, 05:33 AM
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Both!
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Old 12-19-2010, 08:51 AM
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Quote:
Originally Posted by JWP View Post
Quote:
Originally Posted by cookies View Post
sounds like your pilot jet needs to be turned out a bit. did you by any chance screw it in all the way when you replaced it and forgot to turn it out?

Which jet are you referring to? when you look at a schematic, there is 2 pilot jets.

there is only one pilot jet, it's on the front (engine side) lower part of the carburetor. Turn it 1.5 - 2 full turns out (counter clockwise) from being snug.
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Old 01-12-2011, 06:45 AM
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I finally got back to working on this thing last night and got the idling problem fixed. When I had rebuilt the carb, I had left the pilot jet in there since it had that brass cover. With me soaking the carb, the rubber gasket messed up. Last night I took it out and replaced the pilot jet. It will now idle.

My problem now is that when you give it gas, it will bog down and die. Where do I go now with this problem.
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Old 01-12-2011, 05:21 PM
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hmmm... are you letting it warm up before you try to give it throttle? did you put the e-clip in the middle position of the needle when you rebuilt the carb? still sounds like a carb problem to me.
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Old 01-13-2011, 05:44 AM
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I pulled the carb again last night and took it apart completely and put it back together. Did not find anything out of the ordinary. I remember what some one had said about the intake and inspected it. Sure enough, it has a crack in it. Probably been the problem all along.
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Old 01-13-2011, 07:04 AM
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Yeah, those cracked boots will cause all kinds of headaches till you finally figure out that's what it is.
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