I just bought a '03 Sportsman 400. I haven't ridden it much, less then 10 hours. I went out today and everytime I left off the throttle it dies. I tried adjusting the idle but no good. If you just touch the throttle it idles fine. This first 1/16 of an inch seems to be the problem. If I go past this and turn the idle up, the motor revs right up. Below this the idle screw does nothing. Any ideas?

 

Sounds like the E.T.C. switch has to much slack in it! when the machine is turned off check how far you can move the thumb throttle before you can feel it pulling the throttle cable it should have no more than 1/4 inch of free play in it.If you have to much freeplay this is probaly causing your problem,but dont worry it is very easy to adjust. [img]i/expressions/face-icon-small-happy.gif[/img]

 

Good news! Are you going to keep me in suspense [img]i/expressions/face-icon-small-smile.gif[/img] How do I adjust this? Since it is still under warranty should I make the trek out to the dealer?

 

First off did you check and see if there was freeplay in the thumb throttle,and if so how much, if it is more than 1/4 inch try this trick before you do any ajusting crank the A.T.V. up and let it warm up after it has warmed up sit on it and turn the handle bars from left to right slowly and see if this causes the idle of your machine to change in any way.If it does change this maybe a sign that the throttle cable is routed wrong and possible binding somehow,if not then I will tell you how to adjust the E.T.C switch just want to make sure that the cable is not binding before you start adjusting on it.

 

About six inches down the throttle cable from the throttle assembly, you will see a fat area in the cable covered by rubber sleeves. Pull these rubber sleeves away. There will be a threaded adjustment with a lock nut. Loosen the lock nut and thread the two pieces out just a little bit. Do this just enough to keep it running. Do not adjust it so far that it will raise the idle.

 

You guys are awesome! That was it. Thanks a million!

 

A million, "no problem".

 

Hello my problem is it wont idle but when i turn the handle bars all the way to the right it idles...how did i fix this problem

 

Take up the slack at the throttle first. Then when you have 1/8" slack at the thumb lever adjust the carb idle adjuster until you have a steady idle with bars turned back and forth.