Polaris 2004-2005 Sportsman 6x6 - Troubleshooting

GENERAL INFORMATION
4.13
TROUBLESHOOTING
FUEL STARVATION/LEAN MIXTURE
Symptoms: Hard start or no start, bog, backfire,
popping through intake / exhaust, hesitation,
detonation, low power, spark plug erosion, engine
runs hot, surging, high idle, idle speed erratic.
S No fuel in tank
S Restricted tank vent, or routed
improperly
S Fuel lines or fuel valve restricted
S Fuel filter plugged
S Carburetor vent line(s) restricted
S Plugged or restricted inlet needle
and seat screen or inlet passage
S Clogged jets or passages
S Float stuck, holding inlet needle
closed or inlet needle stuck
S Float level too low
S Fuel pump inoperative
S Air leak at impulse line
S Restricted impulse line (kinked,
pinched)
S Intake air leak (throttle shaft, intake
ducts, airbox or air cleaner cover)
S Ruptured vacuum slide diaphragm,
Vacuum slide stuck closed or sticky
S Improper spring
S Jet needle position incorrect
S Incorrect pilot screw adjustment
RICH MIXTURE
Symptoms: Fouls spark plugs, black, sooty exhaust
smoke, rough idle, poor fuel economy, engine runs
rough/ misses, poor performance, bog, engine loads
up, backfire.
S Air intake restricted (inspect intake
duct)
S Air filter dirty/plugged
S Choke plunger sticking, incorrectly
adjusted choke
S Choke cable binding or improperly
routed
S Incorrect pilot air/fuel screw
adjustment
S Faulty inlet needle and seat
S Faulty inlet needle seat O-Ring
S Float level too high
S Poor fuel quality (old fuel)
S Loose jets
S Worn jet needle/needle jet or other
carburetor parts
S Dirty carburetor (air bleed
passages or jets)
S Weak or damaged vacuum piston
return spring
S Fouled spark plug
POOR IDLE
Idle Too High
S Idle adjusted improperly/idle
mixture screw damaged
S Sticky vacuum slide
S Throttle cable sticking, improperly
adjusted, routed incorrectly
S Choke cable sticking, improperly
adjusted, routed incorrectly
S Plugged or restricted idle jet
Idle Too Low
S Choke cable bending or incorrectly
adjusted
S Idle speed set incorrectly
S Idle mixture screw misadjusted or
damaged
S Belt dragging
S Ignition timing incorrect
S Worn jet needle/needle jet
S Plugged or restricted idle jet
Erratic Idle
S Choke cable bending or incorrectly
adjusted
S Throttle cable incorrectly adjusted
S Air leaks, dirty carburetor passages
(pilot circuit)
S Pilot mixture screw damaged or
adjusted incorrectly
S Tight valves
S Ignition timing incorrect
S Belt dragging
S Dirty air cleaner
S Engine worn
S Spark plug fouled
S Idle speed set incorrectly (speed
limiter)
S Worn jet needle/needle jet
S Plugged or restricted idle jet