04 Sportsman 500 smooth idle, but no balls

[ateav8gn]

New to forum....

The 500 will idle fine but sounds like an out of tune 2-stroke snowmachine above about a third throttle. Pulled the plug MANY times to find a black dry plug, clean it, then it will run fine for 3 minutes then cutout, no power. Oil level fine (not overfull), connections good, good gas, pulled intake hose and B12'ed the carb and all intake tract, while installed so no vac leaks. It will rev fine in neu/park but in gear... crap, I can't even get it up the ramps into the back of the truck even if I wanted to take it it to the local stealer.

Bears are out and my time is short here so I could use any help ya'll are willing to provide ASAP!!!

Thanks
ATEAV8GN
North Pole, AK

[Ipaq]

Well, it happened to me in the past. (The reason was clogged air filter)

It looks like you have non suitable gas mixture . (Rich Mixture)
The carboned (black) plug may give you direction.
I would start with these checks:
Check the air filter. Clogged air filter may cause this symptom.
Check for open hose between the air filter and the carb
Check the hose between the carb and the engine.
Check the Carb choke. Make sure it’s not stuck.

[ateav8gn]

Originally Posted by Ipaq

I would start with these checks:
Check the air filter. Clogged air filter may cause this symptom. <- done
Check for open hose between the air filter and the carb <- done
Check the hose between the carb and the engine. <- done
Check the Carb choke. Make sure it’s not stuck.

<-done

All check out good.... took the whole intake tract apart all clean, won't run at all if I touch the choke, never use it unless its -20 or colder...

Any more ideas?

[Ipaq]

Air intake restricted ( inspect intake duct)
Air filter dirty or plugged.
Choke plunger sticking, or incorrectly adjusted choke.
Incorrect pilot air/fuel screw adjustment.
Faulty inlet needle and seat
Faulty inlet needle seat O-Ring
Float level too high
Loose jets
Worn jet or needle
Weak or damaged vacuum piston return spring
Fouled spark plug

[stendori]

is the bike cutting out or is it just seem like it boggs down. make sure the choke plunger is seting all the way down correctly and float level is right.

[Kerbbirds]

are both breather tubes hooked up to the airbox? I worked on one the other day and did a test, left those breather tubes off and it ran like crap, hooked them up and it ran fine.Also check the slack in throttle cable.

[RickCJ7]

Use a new plug! cleaning a fouled plug doesn't work.