2002 Polaris Sportsman 500HO
I have installed my dial a jet and its blowing fuel out of the hole, doesn't matter what hole its in and when you first rev it up is when its doing that I can tell. I called Thunder Products and said it may be a intake valve being tight. I have only 570 miles on it and was told at the dealer that the valves didn't need adjusting till around 1500 miles. I know they said it might look wet around it but I know it should NOT blow fuel out under throttle.
I removed the plug and I have a compression gauge,I can also pressurize the cylinder at 120 psi, There is NO air coming out of the intake or exhaust. On comperssion stroke. SO that rules out valves, I can turn the crank over (Ihave the clutch cover off) and hear air out the intake and turn it over again then it comes out the exhaust another turn and it stops on compession stroke. I have work on cars before I have a little schooling.LOL
I went ahead and adjusted the valves, removed and pluged the mod air box,no sticking valves,and still blowing out the dial a jet. I can remove the fuel line going to the jet and the fuel bowl is not pressurizing because the fuel is not coming up past the fuel level running it . SO thats right and that means the carb is ok. What could cause the intake to blow back if thats what it is. If its a sticking valve there would be a performance problem.
I have posted pics of the way its installed that are under review but should be on here shortly.
WHAT AM I MISSING!!!!!!!!!!

 

I have a dial a jet and never had this problem unless the quad is standing straight up on the rear tires...have you ever turned the white dial with the emlusion screw tight...in the manual that says that doing so will wreck parts inside your D-A-J...other than that i donno what the problem would be

 

No I havent done that, just installed it. We ruled the quad out,thunder products is sending 2 mixing chambers to try and see if that will stop it. If it doesn't they will buy it back.

 

Hey i'm thinkin about gettin one of thoes dial-a-jets soon. Are they hard to install?

 

It wasn't a hard install, but a pain in the A$$ as far as the problem im having. You will have to go down a size or 2 in jets for it to work.

 

Do you have your snorkel hoses hooked up?

 

I have tried it with it on it,but the fuel puddles up in the tube and it the drips out around the boot.

 

I see you have a modified air box, are you using a filter?

 

Yes I have a k&n on even tried the stock filter even removed the mod to the box and plugged off.

 

Dial a jet= Dial a junk..... I have read quiet a few post like this... Sorry to hear your having problems.. If I was you I would send it back....