I would like to try some different jets in my 2001 500 manual and was wondering what all was involved, does the carb have to be removed or can it be changed with the carb in place? Thanks for any info on this.

 

I just did my 400 and removed the carb to do the change. You might be able to get the main jet out without removing the carb if you can drop the float bowl, but I can't say for sure as I did not try to open the patient up this way.

Good Luck Jim

 

I just rejetted my 300 yesterday. According to the shop manual, it has the same carb type as yours. I didn't have to remove my carb, but had to disconnect the intake and outlet ducts, leaving the fuel line, choke cable, and throttle cable in place.

You need access to the top so you can shim the needle, (if you're going to a bigger jet) and to the bottom to replace the jet. I was able to just flip the carb over and get the job done.

 

I to have a 500 man 2001.I changed the main from 145 to 142,I did not go lower because of the cold weather riding that I do,it would be to lean..You can do the change with the carb on,just remove the right side plastic panel then loosen the carb clamps on the air box and the engine inlet.You should be able to twist the card almost to a 90 over ,this will give you access to the float bowl.Once the float bowl is drained and removed ,remove the locking nut(flat head screw driver)then the main jet.If you have never done this it is not to hard,just do not over tighten the main when you put it back in.Hope this helps,it did for me.

 

Just two quick notes on the procedure. Don't lose the float retainer pin and don't worry about the needle position, it's not adjustable on this carburator.

 

You shouldn't need to remove the float bowl. at the bottom of the float bowl there should be a big nut and that is all you need to remove to get to the main and pilot jets. As Roys said just loosen the inlet and outlet calmps rotate the carb so you can see the bottom. Don't forget to turn off your gas.

 

You guys have convinced me to re-jet my carb. Do you get the jets from the A/C dealership or can you get them somewhere else? The reason I ask is Im not too impressed with my local A/C dealer (terrible service) who will probably tell me its too complicated to perform without bringing it in to him for service. Do you just need to remove the 4 screws that holds the float bowl on to the carb to gain access to the jet? I didnt see the big nut on my carb your talking about. Isnt the carbs different between the 2001 400 & 500s? Sorry for all the questions, but want to get it right the first time. Im currently using a K/N filter and a CR7E plug which has increased the performance over the stock set-up. I normally ride between 7,500 and 9,500 feet. Will going to the 142 improve my performance and gas mileage?

Cat3608
2001 500 Manual
K/N filter
"Best ATV purchase I ever made"

 

I have a 2002 500 manual and ride 5000 to 9000 elevation, I run a 140 jet, but the plug is still black like it's rich, but running good. last weekend weather turned cold & snowy and it was spuddering towards the top end while pushing 15" of snow.

 

Cat 3608,Roy here,the 4 screws on the float bowl will have to be removed,philips head if I remember right.I think some people forget that in2001 the carb on the 500 AC is not a Mikuni(somrthing like that) ,it is now a kein carb,thus the different float set up.One thing I failed to mention is the primer pump on the side.It just rotates right out ,so dont worry ,no big problem.If you dont run in minus 8 or lower celius,then I think I would get the 140 main jet.Just rememder to do a plug check at the end.As for the jet ,any bike shop can get it ,tell them it is a 34mm Mikuni carb.Hope this helps ,any concerns just give me a mail.Lots of luck ,Roy.

 

SORRY i GOT THE CARDS BACKWARDS. THAE OLD IS MIKUNI THE NEW 2001 IS A KEIN 34 MM