Hi everyone,

i noticed last night when i was out for a ride there is a slight hesitation between 5-7mph if i give it a quick half throttle (like a bog for a second). Few months ago i did an oil change, air filter, fuel filter, new belt, removed carb and cleaned it and adjusted throttle cable.

In neutral, there doesn't seem to be any hesitation.

where would you suggest i start? Thanks

2004.5 Sportsman 500HO with 2200 miles.

 

Revving it up in neutral usually never tells you a thing as there is no load being placed on the engine in most situations.
Two things i would check. You mention you had the carb off and cleaned it.
Is the rubber carb intake cracked? The part between the carb and engine head. They will usually crack right where the big part that goes onto the carb joins the smaller round tube part.
What you describe could be a slight lean condition caused by a cracked intake adapter or a slightly miss adjusted carb.

 

 

Haven’t had time to dig into this but I did do a test last night. It’s the same in low or high, no difference. Also noticed if your are doing let’s say 25mph and let off on the throttle for a second or two and hit it half throttle . The bog is there.

i did double check the throttle adjuster to make sure I had about 1/8” gap which I do and I’m running around 1250 rpm at idle when warm

i believe it’s carb related. I will check the boot once I remove it.

 

I assume you bought a chinesium carb? and yeah sure sounds like a fuel related problem to me also.
I have read that the carbs are either hit or miss as to weather they work properly or not.
Check that part shown above and if it's ok i would try adjusting the mixture.
This might help?
https://www.manualslib.com/manual/10...age=120#manual

 

Also according to the manual your idle speed should be 1100rpm +/- 200rpm when fully warmed up.

 

No, its the orignal carb. I took it all part today and clean everything as good as i could. for first 10min seem to be fine but there is still a hesitation (i'd say half of what was there before)...getting closer but not 100%

i believe the mixture screw is behind a brass plug? if i do take the plug out are you able to adjust the mixture screw while the carb is installed?

I did order a carb kit for it and will be in on Thursday, hoping that will solve the problem Thanks

 

Yeah i would put the kit in it and fallow all directions. Then give it a try as that may very well solve the problem.

 

Installed the kit and it solved the problem but i ran into an issue that i couldn't remove the mixture screw. I was able to remove the brass plug but when i went to screw it in to see how many turns i would need when i put the new one ....it only turned less than a quarter clockwise...when i tried to turn it counter clockwise..i might get 1 turn and i can't turn it anymore. any ideas?

idle is not as good as before but i have it running at 1300 when its warm...took it for a 5 mile ride tonight and no bog or hesitation.

Thanks

 

Could be a couple reasons.From dirty threads to galled threads.
If i remember right the factory setting is 2-1/2 turns out and i would think it should not move more then 1/2 turn from there.
I would put a little light machine oil in the threads and try working the piece back and forth as you try to work it out gently.
If its galled threads unless you get very lucky somehow it will need drilled out and threads repaired before the new one is put in.
Don't forget to give everything a thorough cleaning before it all goes back together.
Also set the idle to 1100rpm +/- 200