I have a '01 Sportsman 500 HO that isn't running right, anything over idle it starts cutting out badly, if I take the air box lid off it helps some, and if I also take off the air filter it helps more. I noticed that right after I shut it off there is a little gas dripping out of the overflow tube. I'm wondering if it would be the carb float out of adjustment, if so would that make it run poorly? Also what is the correct setting for the float?
Thanks in advance.

 

It's probably a leaking needle valve that controls the level in the float bowl. If you shut off the gas and run it (with air filter and lid in place) the fuel level in the float bowl will gradually drop. When the level approaches it's "normal" level it will run normal until the you run out of fuel. If this test holds true all you need to do is replace the needle valve or it just may need cleaning.

 

I took the bowl off the carb and everything looked clean, cleaned seat and needle. Reassembled still runs the same. The little test of shutting off the gas does let it run right for a few seconds before it runs out of gas. I should mention this is almost new machine with approx. 30 hrs.

 

Best thing to do then is let the dealer fix it.

If it always did this since new, the float may not have been set properly.

Farmr

 

No, this has just started.

 

Everything points to a float bowel level that is too high, the causes can be a leaking needle valve, a leaking float (if it is hollow) or the level is wrongly adjusted, not likely as it worked fine before. All in all I agree with farmr, take it back to the dealer that's what warranty is for.

 

Problem solved! The underlying cause goes back to when I rejetted for my Colorado trip, I thought the foam that rests on the tank to hold the 2 plastic air breather tubes went up under the plastic atop the tank, soooo it was restricting the air intake, which then would help in fouling the plug so it would not run correctly with air breather top off. Glad to have that behind me. Live and Learn.

 

I should have thought of that. My Xplorer did the exact same thing. I have since taken that foam piece, and removed it. It is there to dampen noise, and if you really listen, it may be a little louder, but after restricting the intake 2 times I figured I could live with the noise.