hey, i tried searching eBay for a rebuild kit for you but i didnt see anything for a 96 sportsman 400.... you could just buy the parts piece by piece and replace accordingly..... or e-mail some ebay seller that sell other kits and maybe they can get you one.....

 

you can look at the parts break down on the polaris site to see all the pieces. give you an idear if any thing is missing.now you sure the cable isnt misrouted and the slide is all the way down. if its all the way down in the carb and its running high idle and you choke it and it brings it down to running area then maybe you have a massive air leak some where causing it to run extremly lean.what is the air screw set at for turns. as long as you cleaned the jets out and the passages and the float is working and set correctly then it should be idling somewhat fine. just a couple of idears for ya.

 

Im pretty sure the slide is all they way down I took the carb out and put the slide in while it was out and I can see about a 1/2in of light, I have the cable routed around the tank down the right side of the frame and to the carb, when i choke it it will idle down but not to normal but down alot. I was kind of thinking I may have an air leak also ill check that out

Also thanks for all your help so far.

 

Stendori is on it. If the slide is all the way down you have an air leak. The only way an engine can rev is with air.

 

Ok im gonna go out and spray some carb cleaner around the carb seals and reed cage to see if its leaking.

 

<div class="FTQUOTE"><begin quote>Originally posted by: 300ex90

Im pretty sure the slide is all they way down I took the carb out and put the slide in while it was out and I can see about a 1/2in of light,


seems like a big gap under the slide for being closed, try adjusting the cables till the slide sets on top of the idle screw. it should drop the slide down further, it has to touch the idle screw. i also read where yo said you sprayed out the carb real well but did you actually remove the pilot jet to clean it? it has a pretty small hole that controls the idle circiut and if its plugged it wont idle right or at all, when this happens most people just turn the idle up to make up for a partially plugged jet slowing their idle
then as a last resort they start adjusting the cable to open the slide more to get more idle speed
this sounds kinda like what happend to that quad which may have led to a tear down and rebiuld, now i'd check the pilot jet adjust the cable so the slide drops fully onto the idle screw and then check for airleaks

seems like every 2 stroke i buy has a plugged /partially pluggd pilot jet so i always start there on idle issues