i have a 94 sportsman 400 that i just had the engine rebuilt. i started using amsoil premix80:1 for the first time. i bought a new cable and blockoff kit to do away with the oil injection setup. when i put the cable in i noticed that where the cable goes into the carb that the black part around the metal cable had slid up and was not in the carb. you could pull it up with your had and the motor would idel up because your were pulling the slide up with your had. the problem i was haveing was i had slack in the cable and it was not letting the quad move until it got to about 1/4 to half throttle and it seemed to just not have any power at all until you got up to speed are past half throttle. i did not know at the time that it was slack in the cable that needed to be ajusted to fix the problem. well i ajusted the slack and then it started running great. very responsive. the only mods that i have is a delta v-force reeds, dynoport pipe and clutching by rick ritter. i did not have the head milled are cylinder ported. i had a 230 main in and needle clip in the middle. a 30 piolet jet and air screw set at 1 1/2 turns out. the pipe in extremely lound now so i took it off and put back on my factory pipe.. i rode it around for awhil and when i slowed down to put it in low i fouled a plug, it was black. i put in another plug and went home. the next day i put in a 220 main and went 1 1/4 turns onthe air screw. i rode it around and it was sounding like it was trying to load up real bad. now i had my wife and kid on there with me so i could not open it up. anyway the throtle cable stuck on me and i had to shut it off. i ajusted it at the handle bars and rode it about 2 miles to my house.it would stick on me several times before i would get home. the hole time it would run good when i had it at half throttel but when i gave it a little more gas it would shut of and almost die. i was just about home and it fouled another plug.now this plug looked alittle white.but i only had it in about 10 min, and i am running amsoil, whick is said to burn real clean. i put in an old plug that i had and it fouled it in about 15 sec. i pushed it back and i looked at my cabel and it the black part was out even futher. so i took off cabel and i ordered another cable today. also when i have it i neutrel and reve it up a little it sounds fine but when i but it in gear at first i here a knocking sound that goes away after i ride it some. it is just when i am creeping along. is this my clucth buttons going out. and what should i do about jetting. i live in lousiana

 

i am going to marango ride on june 1 and i would like to get this fixed before the ride

 

[img]i/expressions/face-icon-small-smile.gif[/img]Hey maximus, I live real close to you in Arkansas, so we would jet about the same. If I am not mistaken, the factory jet with the stock pipe for yours should be a 200 main. You probably would need to come down off the pilot a little as well and fine tune with the air screw. But ultimately you should be real close to factory specs on the air screw when you get it right. With a dynoport pipe you have to jet up about 20%. As far as the knocking noise, a hard clutch malfunction will not go away as you drive it.There isnt really anything in there that can do that without badly affecting operation of the machine. If there is anything wrong, a good physical inspection should see a problem. I can tell you that a 94 model would be due for a complete primary and secondary rebuild if it hasnt already been done.The other things to remember are that the clutching will be designed to load the motor more because of the torque gain of the pipe, and that the v-force reeds actually make your motor run richer due to efficiency gain. Hope this helps,Bubba

 

i took off the dynoport pipe and went back to the factory pipe. i dont know if the knocking noise goes away after i get it up to speed or not because i cant here it then. i can here it when i am putting around and give it a little gas. all i have done to my cluthches was have different springs put in. nothing else.