Hi Everyone, I have a 96 Sportsman 500 and I"m replacing the choke cable. The question is how do i adjust it? There is a threaded sleve on the carb end to adjust it. I have the Polaris shop manual and they only describe how it works, Polaris calls it a "starter system". I played around with it and it will make a diffenance in the idle. Thanks

 

Not sure about your specific model, but for manual chokes in general you should adjust it so that when you push the *** in (off position) it should not go quite in all the way. You should have about 1/64 of an inch of space. This way you are making sure the choke will be all the way in the open position when running.

You should get no high idle when it is in the off position (*** in).

It is important to make sure it is opened (*** in) all the way when not needed (engine warmed up).

Sorry this sounds confusing. You might be able to look into the carb with the air cleaner off an see the correct motion of the choke.

 

You adjust it like you said at the carb. After choke cable,plunger,and spring is installed and choke lever is in pod, loosen the 10 mm lock nut at the cable end at the carb while holding the 12 mm choke fitting that goes in the carb. Ater loosening the nut you can turn cable out counter clockwise to tighten and back in to loosen. Adjust to where you have about 1/8"slack at the choke lever and tighten locknut. OPT

 

Thanks old polaris tech and luvmudd, I have it adjusted, I tested it cold and it starts right up in 10* degree weather, "1/2 choke" sounds normal.
Thanks for the help again