This past weekend I rode my 02 Sportsman 500HO quite a bit after having some issues with electrical connections. Everything was great, it rode like a dream. I get it home and the next day I smell gas in the garage and I see that the float bowl was leaking gas out the drain hole. I took the carb apart today and it looked pretty clean, I had a replacement needle and seat kit and figured what the hell and replaced it to see if it would help. No deal. Still leaking and it won't even idle properly without the choke on. Can't even rev it up without it bogging and dying either.

I just took it apart again and cleaned it well, inspected the top needle and the jet below, everythings clean. I have the Dynomax jet kit in and it has been running great since i tuned it and put it in last winter.

It's still barley running with the leak. I've never had the carb all the way off the bike before either. I've always worked on it by flipping it around with everything disconnected except the wires. Is it easy to disconnect the throttle cable and choke? I think the next step is to check the float position, but I can't do that until I get it totally off the bike. Any other suggestions are very appreciated. Thanks.

 

How do you take the throttle cable and the choke cable off?

 

when upside down float mounts should be horizontal,i set mine slightly down upside down,,,,,,,make sure neither float full of fuel