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Old 05-02-2010, 09:20 AM   #1 (permalink)
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Foreman 450 ES only run on choke

I have an 02 Foreman 450 ES that has been sitting for a couple years. When parked it, it was running rough. It would idle rough and miss once in a while. Sometimes causing it to stall. Upon acceleration, it would miss and sometimes "backfire" through the carb.

I have removed the carb and blowed all the jets and orfices out like the service manual tells. I also readjusted the valve clearance. They were about .010. I reset them to .006 as manual states. I have also flushed the gas tank out and put fresh gas back in.

This thing is driving me crazy! Now I'm not an atv "mechanic" to speak of, but I do know what I'm doing. Does anyone have any ideas? Could this be an electrical isssue? In the past, I did have a few wires chewed on by mice. I fixed them all, unless I have missed something.

I can get it to run only with choke on but it runs rough and will not accelerate.
Thanks!

Last edited by Merlin; 05-02-2010 at 09:24 AM.
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Old 05-02-2010, 09:33 AM   #2 (permalink)
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If it will only run with the choke partailly on then I have to say you have a clogged idle circuit. I know yoou blew out the jets and orfices but did you remove the jets? Did you use carb cleaner before? I would suggest that you remove the carb again, remove both jets and the pilot screw and any O-ring as carb cleaner will destroy them. you also could have a small crack or tear in the accelerator pump diaphram piston. Also you may have a bad carb heater. Some of the utility guys have more experience with these carbs, they should be along shortly.

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Old 05-02-2010, 12:21 PM   #3 (permalink)
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I would also say that the carb. Still has a little trash still in it somewhere. Also the timing could be off a little.
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Old 05-02-2010, 10:31 PM   #4 (permalink)
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yep..i agree..carb jets are stopped up..go back through it..and pull the jets..clean them out with a wire from a wire brush..nothing bigger !.
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Old 05-02-2010, 10:40 PM   #5 (permalink)
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yeah i agree carb issue
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Old 05-03-2010, 12:03 AM   #6 (permalink)
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Yeah, I agree. It sounds like the carb still has some debris in it somewhere. Also, make sure you check the rubber vacuum piston in the top of the carb. It could have a hole in it and that would cause it not to want to accelerate, because it wouldn't raise the needle.
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Old 05-08-2010, 11:44 AM   #7 (permalink)
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Thanks for the help. It actually was the idle jet plugged up. Initially I just blew everthing out, but then went back and took all jets out and looked through them. The idle jet was clogged almost completely shut. I cleaned it out with a torch tip cleaner. Now it runs much better. Thanks again for the assistance.
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Old 05-08-2010, 11:55 AM   #8 (permalink)
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Glad to hear you got it fixed!!! Welcome to the Family!
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Old 05-08-2010, 12:39 PM   #9 (permalink)
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Yeah, glad you got it fixed.
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