2002 Sportsman 500 HO carb issue

[rsrogersnt]

Started leaking out the overflow so I disassembled and changed o-rings. I removed the adjuster (see pic) counted turns to remove and re-installed with same turns. Crank it up and the idle is way to hign - idle adjuster is all the way out - I don't understand - it is the only adjustable part and I put it back like I found it. Any help would be great - supposed to ride this weekend but not till I get it right!! Thanks

 

[mxz sledhead]

without looking at it sounds like fuel valve is stuck even when with motor not running fuel by pass the valve and leak out the over flow maybe pull the bowl off see if the see if float and fuel valve are not stuck that first things that i check

 

[rsrogersnt]

what fuel valve are you refering to?

 

[Garryese]

The arrow in pic#1 is the idle mixture adjustment. Idle speed is adjusted with the tube/thumb screw that is in the foreground of pic#1 and at the bottom of pic#3. I cannot tell for sure, but looking at pic#2, it looks like the butterfly is open too far.

If the idle is way too high, look for an air leak between the carb and the cylinder head. Or make sure the outer throttle cable is properly seated at the carb.

If the idle speed changes as you turn the handle bars, you have the throttle cable routed incorrectly or it got snagged on something during reassembly. You should have 1/8 free play at the throttle lever reguardless of which way the handle bars are pointed.

If the engine loads up once it gets warm, make sure you have 1/8 freeplay on the choke cable.