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Turns out there was a small crack in the rubber carb boot as well. Should I turn the fuel/air screw back to 1 3/4 turns out where it originally was, or leave it at 2 1/2 out?
You might try adjusting the throttle cable, after 6 years it might be stretched just enough to not idle when cold. Corrected the same type of problem on 1 of my 02 500s.
Sounds like there is a misunderstanding here! The throttle cable should not have anything to do with the idle level - if it does, then it is too tight. When the throttle is at "idle", the throttle lever on the carb must rest on a stop, typically the idle screw. The motor should idle at the proper RPM with the cable disconnected....
I had to order a new exhaust gasket & carb boot, dealer didn't have either on hand. I'll report back next week with results. Thanks to all for the advice.
Well, that didn't help at all. The idle speed is still erratic, varies by 700-800 rpm. I noticed my oil smells like gas too. Any other suggestions? Thanks.
Anyone know how to disconnect the throttle at the carb on an '04.5 500HO? It's not the slide type throttle I'm used to, the throttle is on the right side of the carburetor. thanks.