Question about Polaris ATV

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2004 Polaris Sportsman 400 - Engine cuts out when climbing hills or when pulling a heavy load? The engine wont shut down on me but it looses its power and sputters until it gets to level ground. I had a ATV mechanic tell me it was the air flow and that the machine wasn't getting enough air, but I was thinking it's a carb issue? Thank you in advance for any assitance you can provide.

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Well there are a couple of things that can cause this to happen. first check your oil and coolent. odd sounding i know but this can cause it. second check and make sure your cluchs are working correctly. next if all that fails then i would check the air intake for blockages and then service the carb.
reply if you need more help :)

Posted on Aug 03, 2010

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I also have Polaris 400-the bogging on hills and under load is most likely a jetting issue. I just rejetted mine to a 167.5 main jet (hex head mikuni) and have taken to the mountains without issue. This is well known problem for this year and model. Bought jet for $4.50 from dealer and about an hour of install time.

Posted on Mar 29, 2011

  • Jim Wright
    Jim Wright Jan 29, 2013

    I have this same problem on my 2004 polaris sportsman 400 I'm not to good with engines so i was wondering how hard it was the really rejet the carb?

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IT'S A TWO STROKE. SOUNDS LIKE IT'S JETTED TOO RICH.CHECK THE PLUG. IF IT'S BLACK ,JET DOWN..WHEN YOU CLIMB THE AIR GETS THINNER AND YOU HAVE TOO MUCH GAS.
HIGH MARK

Posted on Sep 05, 2010

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I have a 2004 Sportsman 400 with same problem. I've completely disassembled and cleaned the carb. Found no problems. Removed and cleaned air filter. New fuel filter. Does anyone know if this model has a fuel pump. This is the only thing I haven't checked. Does anyone know if there is an adjustment screw on the carb I could adjust?

Posted on Sep 17, 2010

  • kurkosky_91 Dec 06, 2010

    yes there is an adjustment screw for the carb. i belive it is on the left side of the machine. just pull the side off and feel 4 the screw

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