I need help finding a jetting chart.
I need to know what jets to run at my elevation.
I (my wife) has a 2004 Sportsman 400. I have had it back to the dealer for the service bulliten re-jetting, but it still bogs and cuts out on big climbs. I want to know where my jetting should be for my riding.

Thanks......

 

We need to know some more info.......like where it bogs out at(idle, mid......or high rpm).........and what elevation and temp.......

 

It bogs/cuts out on steep climbs over 25 feet long or so. The areas we ride are between 3000-5500'
It has done it at 70deg and 45deg. After the dealer did the re-jet, it was 85% better. It seems to start by loosing power then acting up. It seems like the engine gets drug down then starts to really bog/cut out.

I am wondering if the 400 is just so under powered that I may need to do some clutch work to get the engine to stay tached more so the engine cleans out.

 

I sold my 400 and got a 500 it seemes better the 400 has the power but the 400's are a pain if you use them at mutible altudes I plowed with mine it was great but once summer came and it was warm I and range from 8000 (were I plowed) to 12000 feet I could never find a happy median.
the 500 HO is great I plow then move right to summer fun with no problems.
p.s. I did have some cluch work on the 400 and the 500 for more lowend torq

 

How is it on level ground? If it is revving up fine there and pulling all the way through the powerband, then it's probably not a jetting problem. Might just need to adjust your floats if it only happens going up and down hills.

 

I doesn't bog out on flat, but it doen't seem to have the power it should. The last time I rode it I could onlt get 5500rpm & 45mph out of it wide open. After it was crapping out I took the air box lid off. On the way back to the truck I could get 5850rpm and 55mph. It almost seems like the engine gets loaded down on long pulls and it can't clean out the fuel going in.(on the climbs)

 

I had mine re-jetted. The 2004 400 machines were jetted too rich at the factory. They jetted it with a 172.5 main jet and it's too rich. I would also get the bogging down BS on hill climbs. I changed mine out to a 167.5 and it is now no longer an issue. I just got back from riding in the White Mountain area of NH and the elevation was about 3000 ft. max where I rode. I did loooong steep full throttle hill climbs repeatedly in high gear range without any bogging, coughing or power loss what-so-ever. It is probably good at somewhat higher elevations as well because it didn't have any problem at all at the 3000 ft. My normal riding elevation is basically sea-level and it runs great there too. This is obviously the right jet for me.

Since you run at a significantly higher elevation then you may need to go leaner (maybe a 165 main jet). I just wanted to convey that the 167.5 jet seems right for my elevation zone.

Also.......an interesting note. I looked at the jetting chart in an owners manual of a brand new 2006 Sportsman 450. It has the new bigger 455cc version of the engine but uses the same 34mm carb. The jetting chart for that (more powerful) engine is leaner across the board than the jetting chart for our 2004 425cc/34mm machines. This confirms to me that they blew it at the factory on the 2004 jetting and went way too rich.

 

Also......I switched out my primary spring to an EPI Pink primary spring ($20 and super easy to do). It allows for a little bit more rpm when doing hill climbs. This keeps it "spooled up" and in the meat of the torque band a bit better. This is NOT a radical spring at all and has no other ill-effects. It just helps to prevent it from bogging down by allowing a slightly higher RPM while accelerating and climbing.

My recent trip doing MAJOR LONG STEEP hill climbs in high gear range at full throttle with this set up has shown me that the 400 may not be a "Muscle Quad".......but it has plenty of power when set up right.

If I were you I'd try the 165 main jet and the EPI Pink spring (Or equivilant spring by another manufacturer). You can also change out your clutch weights as recommended for your elevation as outlined in your owners manual.

 

Question.....when the dealer did the service bulliten re-jet......what main jet did he put in?

 

I don't know much on the newer 400's but i got the impression that your jetting is too rich or maybe you have a clogged jet. I don't think a 400 should be bogging down on hills.