With the clutch cover off run the engine in neutral for a while at different rpms to dry up any remaining water in the clutches and belt. Watch your foot,get on and place in low range and take off. If water was the only problem then it should pull good in gear. If all is good and well just find the souse of the water. Again usually the engine to clutch seal or the cover seal or possibly a little of both.

 

Cool. Thanks. I did what you said and it is moving now. It does seem to be a bit "jumpy" when putting it into gear--any thoughts on that?

 

Try lowering the rpm if it's above 1080 rpms and see if it helps. If it's idling normal,but still jumps in gear or creeps,could have a burnt section on the belt or the clutches may still need to be dried out some more. If it continues to jump or creep and the belt isn't burnt or missing teeth,the clutches may need to be looked at. Look at the link I posted on clutch creeping.Goes into good detail on what can be done to solve this as this was a common problem on 2000-02 models.

 

Great. Thanks. I really appreciate the help.

 

The other problem with this machine is it doesn't idle well. I'm lucky if it idles for 10 seconds without having to give it gas.

 

Make sure the thumb throttle slack is about 1/8" max or the machine can die. If throttle is adjusted correctly and still dies,probably time to install a carb kit. Here's a good Japanese Shindy kit. New Shindy Carburetor Carb Kit Polaris 500 Scrambler 1998 2002 Sportsman 01 02 | eBay Plus float level is critical on this carb or it can cause bogging or fuel dripping from the over flow. Look at this post on the Bst40 carb that's similar to yours.Has some good pics on the carb parts. The BST-40 Bible | Adventure Rider

 

I did the throttle thumb adjustment and had a dealer check it out. Guess your right about the carb.


As I am putting this together I notice a small clear hose with a tiny in-line filter coming out of the bottom of the carb bowl--it is just sitting there. Shouldn't it hook up to something?

 

Hooks to the bottom of the carb bowl nipple. Serves a dual purpose as a drain tube for the carb bowl as well as the overflow tube if the float level gets too high.

 

That's how it is hooked up now. So it is open-ended and just lies there?

 

Yes...