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2004.5 Sportsman 400 barely runs - going back to dealer

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Old Jun 28, 2004 | 04:39 PM
  #1  
AJC629's Avatar
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

My friend's first time out on this brand new quad ruined our trip. Rode downhill about 6 miles to the first trailhead which is steep and uphill. The darn thing would barely run under load. I tried it in low, hi, 4wd, 2wd, and nothing. You could be pegged full throttle and the bike would barely make it. It even stalled out on him a couple times. I'm not a mechanic, but it feels like riding with the choke stuck open, but the exhaust didn't smell like gas. He rode 25 miles of rugged up and downhill like that, thinking if it was something in the carb it would work it's way out, but by the time we got back to camp it had gotten worse.

Anyone else had this experience?
 
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Old Jun 28, 2004 | 06:31 PM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

Had my choke cable set to tight ... caused stalling at idle when turing the handle bars left or right, could be the same issue.
 
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Old Jun 28, 2004 | 06:37 PM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

How do you loosen?
 
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Old Jun 28, 2004 | 06:42 PM
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yaK
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

there was a problem with the jet on the 04.5's that caused it to die on steep incline's! do a search on here for this problem....
 
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Old Jun 28, 2004 | 07:22 PM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

open the headlight pod and there's an adjustment nut on the back on the choke cable.
 
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Old Jun 28, 2004 | 08:17 PM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

I'll let him know. I did various searches looking for jetting probs but couldn't find anything on it. Thanks for the info!
 
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Old Jun 28, 2004 | 08:52 PM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

Here is the link for the thread you need to look at. My 400 had the same problem. A Dynojet kit cured the problem.
 
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Old Jun 29, 2004 | 08:48 AM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

Yes, there was quite a few of us running into this problem on here...You r friend needs to drop the main a size and go from there.. I ran into the issue while way up in the mountains, Steep uphill, and anything over 1/2 throttle would kill the motor.. I dropped the main 1 size, which solved the problem.. Since have installed a Dynojet kit which helped even further.
 
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Old Jun 29, 2004 | 07:43 PM
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Default 2004.5 Sportsman 400 barely runs - going back to dealer

I've seen this a few times on the chat rooms also. I'd have the dealer replace the main jet, sounds like that is the closest fix, i believe a 162 or 162.5 main jet is the fix. Take it back to the dealer and have the dealer call Polaris to cover it under warranty if you have warranty left, if not see if they'll do it anyways, you can't be too far out

good luck
 
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