2004 polaris sportsman mid throtle breakdown
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2004 polaris sportsman mid throtle breakdown
600 sportsman runs great with air filter box off. as soon as box put on it breaks down at about 1/2 throtle, it sputters and back fires. put in shop replaced cdi, stator, coil, rebuilt carb, new fuel pump, and sent back said couldnt figure it out. any ideas.
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Stock jetting was a 45 pilot jet and a 155 main jet(before 10/2/03) a 157.5 after 10/2/03. Main thing is that you do have the separate cdi and coil and not the early model 600 that had the Ducati ignition with the combination coil/cdi. I'd go ahead and jump up to the 157.5 as there isn't a heck of a lot of difference between it and the 155 and go from there. Polaris machines are jetted with the air box and filter installed.If you have decent compression,125 psi or more,have good spark,go into the carb first. You can get Mikuni jets at most area dealers or online.https://jetsrus.com/a_jets_by_carbur..._selection.htm
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Can you pull the plug after this 1/2 throttle breakdown and post the pic? As you move to 1/2 throttle you really come on to the needle jet and come off the idle circuit (pilots)...so I'm curious what your needle setting is if adjustable. I'd also make sure it's installed correctly (you'd be surprised with that one).
Another area overlooked is the choke circuit...
I'm guessing it's running very rich...since putting on an airbox will most certainly restrict airflow.
Not sure how this is electrical if it runs fine with the airbox off...but ya neva know...
Another area overlooked is the choke circuit...
I'm guessing it's running very rich...since putting on an airbox will most certainly restrict airflow.
Not sure how this is electrical if it runs fine with the airbox off...but ya neva know...
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Ipmcelroy
Polaris Ask an Expert! In fond memory of Old Polaris Tech.
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07-23-2016 01:48 PM
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