Okay, so I decided to break out some tools - which is a daunting thing - if you're me.... [img]i/expressions/face-icon-small-shocked.gif[/img]

Anyway, I pulled the aircleaner and sprayed it down - looks great. I cleaned the fresh gas out of the airbox and then proceeded to drain the carb. It did look like there was some crap in there, but I can't be sure, as the catch-pan was underneath my machine, but let's just say there is.

I checked the chocke cable and toggled it back and forth - it's stiff and I gave it a little extra presssure when I set it to off. I also noticed that the assembly on the handlebar was loose. My best guess is that it was left loose after the dealer mounted the winch switch - could something be bound up, or caught in there? I ran the cable down to the carb, but honestly, once I got there, I didn't know what the hell to be looking for.

I also pulled the plug and it was totally, completely black. I cleaned it off the best I could and fired it up, (without the aircleaner) I was going to take it for a spin on the pavement, but a rainstorm was brewing. It sounded great. I also added Seafoam to the tank, which is where my next question is:

It says you can inject thus liquid directly into the carb while it's running. Anyone have an idea how to do this?

Going to take it for a spin tomorrow to see if things have improved.

Any other thoughts would be unbelieveably appreciated....

 

You say your plug is completely black?? I would say you are running rich, jet it down I dont know what you have in there for a stock jet size (I guess 152??) even better, get a jet kit, cleans up throttle response, both are easy to do.

 

Don't be changing jets without finding the problem first (I doubt it is jetting). This is a new problem if I remember right? The stuck choke (enrichener actually) will cause you to run rich. That carb needs to come apart if what you have done hasn't fixed it (it's possible that's all it will take). Should replace the plug in any case. You have to have the airbox lid off and the air filter removed to squirt anything into the engine while it is running. A thought and it is free, try a test run with the lid off and the air filter off. That will lean out the mixture. If it runs better then you will know where you need to go to fix it. If it ran fine before the service then something got screwed up then. You altitude is not high enough to need rejetting unless they screwed up and put too big of jets in at the factory (very unlikely). I think the enrichener has gotten water in it and is corroded and sticking open. Easy fix, pull the valve apart, clean corrosion off of valve and inside the hole with very fine sand paper, clean with WD-40 (or whatever is you favorite) and reassemble. It should move freely in any case.

 

Thanks Bear - I won't be changing the jetting at all, as I can barely change a spark-plug, (yet).... [img]i/expressions/face-icon-small-smile.gif[/img] I picked up a new sparky today. Yesterday, I drained the carbs for well over a minute, (fuel on). The gas was nice and clean. I talked to the dealer today and explained that I was not trying to blame him, but that this issue absolutely was not happening prior to my 300-mile service. I suggested that perhaps the tech seated the valves too tightly. The service manager actually thought that it was a possibility and told me to bring it in if the spark-plug and running the SeaFoam didn't work.

It's suggestions like yours, (and others) that have helped me to at least have some cohesive thought when I try to explain the problem. I also suggested that if I bring it in, that someone try to run it under load, (up hill), as the problem does not really become apparent until then. The only other trick I have up my sleeve is to try and adjust the mix screw, (suggested to turn it out 1/2 to one full turn from someone at another site). Until today, I didn't have a tool that could reach it without pulling off the carb. Still wondering if it's phillips or slotted, but I think I can get this mini-rachet up there.

After that - I'm all done. I know my capabilities, (or lack) and don't want to push them yet - after all, even though it's an '03' it's a new machine. I'll take my chances with the dealer and be better armed thanks to all of you. I have a service manual coming and hopefully will be making deeper forrays into fixing my own machine.

 

I was thinking there was a possibility of a tight intake valve, but it should also idle like crap. Sounds like you have a good dealer. If his guy screwed up he should not charge you for this trip. Turning the idle mixture screw might help, but it does not have much effect on upper RPMs, just mostly at idle and just above. The screw is slotted.

 

I stand corrected bear [img]i/expressions/face-icon-small-blush.gif[/img] wasnt reading the whole post before I started typing (I am a blonde you know), thanks for finding my mistake and pointing it out to everyone [img]i/expressions/face-icon-small-tongue.gif[/img]

 

I didn't want to be the only guy to be wrong and have everyone know it. Then again it is a pretty big club.

[img]i/expressions/face-icon-small-happy.gif[/img]

 

Well, drained the carb again and replaced the spark plug. Runs like a top, but still loses power up hills, (not as bad, but still very noticeable). Couldn't get to the mix screw without pulling the carb, or at least the starter out, so I'm going to run this tank of SeaFoam treated gas out and wait until Sunday - help is on the way, (brother-in-law)...If all fails, back to the dealer she goes.....