Thanks Harley. Throttle free play seems right it ran fine yesterday [ for awhile] till it got hot not over heating hot just normal. after using low range for awhile it started blubbering and missing so I let it cool down and it ran fine I had returned the fuel pressure gauge that same day so I didn't have It hooked up at the time.
I think I will replace the regulator the one that's on it now runs about 50psi. I will post back when I get it and get it changed

 

Well I got to work on the atv today got down to pulling the tank and the little vent hose by the cap was broke no deal I thought till I traced it down. its runs down inside the pipe that holds handle bars, Here's my dumb question I can't pull it out not without force is it connected to something or is run in there just to keep dirt and gunk out.
Crazy I know.

 

Got an 2004 500 carb vent hose is just run into handlebar tube[ there is a small spring clamp] near handlebar clamp block it runs threw?I think if its a vent it should be not hooked to anything? not sure about the efi model

 

Thanks trailrider I was think it might be like a check valve or something on it. The last time I rode it I got it back in the shop
just be for it completely quit I shut it off just before dyed but I could start it but it was running bad I done that acouple times
shut it off and heard a pssssh like something vented about two seconds long. kinda weird.

 

Like 850 said it's just a vent line for the fuel tank. I'm surprised it wont pull out of there though. Polaris did use the same style cap(that underneath the cap on the coolant overflow tank) and ran the vent line through it into.the steering post. Maybe that's what holding it from coming out. The older machines, didnt use the cap with the hole in the center of it.

 

The electric wire I seen may have just been a wire holding the vent hose in place. I have the parts now just trying to get the time.

Ok one more edit, The last time I used it I barely made it back but was still running I shut it off and started it a couple times the last time I heard a psssh like pressure releasing but im not sure where it came from.

 

More problems I noticed today I had a little antifreeze leak after running the machine I replaced fuel pump and regulator today but I didn't get to test fuel pressure the new pump has a better sound to it.
Anyway after I let it run a bit I noticed coolant in the floor the only place I could see it come from was the bottom most bolt on the water pump cover it didn't really look like it was coming from between the cover and gasket just a drop at a time on the bolt head. If the pump goes bad is this bolt designed to leak someway like a weep hole I couldn't find a weep elsewhere.

 

Here is where the water pump weep hole is. I hope it is visible on the forum. One other thing is this motor is sitting on the floor and not oriented the same way it sits in the frame.

 

Thanks Harley. Its been few days since I've been on here been waiting on parts and then time to put them on. I replaced the fuel pump and regulator first and sprayed out the throttle body it sounded and ran better idle was right on 1180 after that. About that same time I noticed an anti freeze leak so I replaced the water pump seal an oil seal also replaced the t bab boot if that's what its called [the boot between the breather box and the throttle body] fuel filter and both exhaust donut gaskets now the idle is low 1120 rpm it also has a miss just kind of a dead spot when its at idle but runs much better down the drive and is much more responsive.
Would anyone have and idea why the idle is low now I did spray the throttle body out again with CRC throttle body cleaner and I didn't run it much any ideas guys?

 

I worked on the atv this eveing alittle while I didn't accomplish much but I do have a wandering I replaced the TBap boot but not the sensor or plug. My question is if you unplug and unplug the sensor shouldn't this make a difference in the way the machine runs Im just trying to narrow down the idle problem its at 1120 rpm and has a miss now.