Polaris Sportsman 90 won''t rev solution

BarnyardEngineering

Well-known Member
Location
Rochester, NY
The kid keeps asking about his 4 wheeler, and I want this d*mn thing out of my shop, so I've been going at it.

I've tried every setting on the carburetor. Someone told me the aftermarket carb main jet was too small, and indeed it was much smaller than the OEM carb main jet. Tried the larger OEM main jet in the new aftermarket carb. Tried the OEM needle in the aftermarket carb. No dice. Just fell flat on its face.

Out of frustration, I threw a Hail Mary and put the air box back on. RUNS LIKE A TOP! Who knew? It needs the restriction from the air box to not run lean.
 
I went through the exact same thing with a Polaris.

It had sat with jelled green gas and water in the tank, cleaned everything up, drilled out the plug over the idle screw.

It would idle good, but way lean on any throttle.

Finally found a very brief mention on Youtube about needing the air box assembled.

Put it all together, ran perfect! Now to get that wasted 10 hours of my life back! LOL
 
Club Car gas golf cars are like that. The air box restriction is calculated into the running mixture. It s too lean
with the filter box off.
 

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