How the heck do you get it off?

Thanks.

 

If its like the scrammy, you have to drill the brass cap and then screw a sheet metal screw in it and pull it out. I think I used an 1/8 inch bit. If this is the case make sure you don't drill too deep and hit the screw.

 

Polaris has a "ATV Team Tips" bulletin that they issue to dealers/service techs. My dealer gave me one he had for the 600/700 Sportsman models. Unfortunately he didn't have one for my 400 but he assured me that it also applicable to mine as well so far as the plug removal goes. Apparently the pilot screw has this wonderful little brass plug installed so as to prevent adjustment. This little brass plug was mandated by our friends at the EPA to meet air quality regulations.

Under this bulletin which is entitled "Sportsman 600/700 starting and drive-away improvement" it gives a complete set of instructions on how to remove the plug and re-adjust your pilot screw. You may want to get the bullitin itself from your dealer......but here is a summary of how to remove the brass plug itself:

* Remove carb from the machine.

* Use a 7/64" drill with a depth stop set at 3/16" and drill a hole in the middle of the plug.

* After it's drilled, screw in a standard sheetmetal screw being careful not to push the plug inward.

* Once the screw is threaded in sufficiently pull it and the plug out with pliers.

The bulletin gives a whole run down on how to re-adjust and set up the pilot screw, needle jet, jet needle, clip, etc......but like I said this bulletin is for the 600/700. But you asked about removing the brass plug.......I believe it's the same relative to the plug.

Good Luck, Bob

 

Thanks a lot.

 

Just FYI:

4-strokes use a fuel screw, 2-strokes use an air (or pilot) screw.

If the screw is on the engine side of the carb, it's a fuel screw.
If it's on the airbox side, it's an air screw.

Turning a FUEL screw OUT makes the mixture RICHER from idle to about 1/8 throttle.
Turning an AIR screw OUT makes the mixture LEANER. (on 2-strokes, you gotta be careful not to get too lean. TOO lean = seized)

 

jeff, like the guys said, get a sheet metal screw, drill the hole, but stop just after you get through in order not to hit the mixture screw, screw in the sheet metal screw and grab it with a pliers and pull it out...

 

TTT for people. I just used it and it works

 

what are the benifits to removing it? should i try it on my 500?

 

We are removing it because you need to change the idle enrichment. If you are doing a jet kit, yes. If not and your machine rides good, probably not.

 

I need to adjust the pilot jet on my 2004 SP700. I can see the little brass cover and I know how to remove it (from this thread and I have the Polaris bulletin), but how in the heck do you get access to it in the first place? Do you have to remove the carb? There's precious little space in there... I can get my finger on the brass cover but I can't imagine how to get a drill into that space.

Removing the carb seems like a lot of effort. The fuel tank has to come out, which means hassling with all the fuel lines, the airbox comes out too, etc. All to loosen the hose clamps that hold the carb to the engine. I think I can do the adjustments to the pilot with the carb installed by using a VERY short shaft screwdriver, so it seems a shame to pull the carb just to remove that plug.

Any tricks here, or should I just knuckle down and tear into it?