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Sportsman 500 from 1999 issue is idles too high

I had to clean the carb and it runs very nicely now.
I completely took it apart.
But it idles too high so that you can not put it into gear without it grinding.

I set the idle speed adjustment knob as low as it will go down on the carb. Still not low enough.

I thien took off the throttle cover on the box attached to the handle bars and if I disengage the cable, I can make it idle nice and slow so the gears work.
If I let go of the cable, the motor stalls out since it is moving the throttle in the carb and It must be able to shut off all the air flow.

It looks like I could grind with a dremel the throttle lever or the round stop and make it work fine.
But honestly why is the cable not long enough now for it to idle slowly?
Makes me think I put it together wrong, is anyone aware of issues with the throttle cable?

Is there some internal carb cable adjustment I did wrong?
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GSE Trail Tammer Exhaust

I installed a trail tamer muffler on my 2013 8oo max the other week. here are my thoughts:
looks great from the rear. The build and fitment were very good. easy to install and bolted right up.
Much lighter than stock but sorry I did not weigh anything.... Next, it sounded great in my drive way at idle. Camping with friends I was curious if it would be too loud? the guys would notice my bike louder a little but mostly they said a throater sound :) . Next riding in the desert it seemed to be almost the same at lower throttle setting and only loader when hard on the gas. I have to say I Love the new sound especially when in narrow canyons and with helmets on it never seemed too loud...
next trip I will let someone else ride so I hear from a distance. I am Very Happy with this new muffler....:grin
Posted on

Over charging.

On my 93 trail boss 250 the etc and speed limiter were causing a problem so i un hooked the black wire from the speed limiter to the circuit board according to the trouble shooting manual. This allows 4x4 to work in reverse without pressing the override switch which i like for plowing snow. now about a week later my lights are blowing out and battery is showing high voltage. At half throttle im getting 16.5v dc at the battery. I assume that the speed limiter and voltage rectifier are not tied together according to the wiring diagram. Im replacing the voltage rectifier but is the speed limiter and etc connected to it somehow? Or was it just a fluke that the rectifier went bad around the same time?
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2017+ Ace 570 & Larger Tires

Hi! So, I took an ACE off of a friend who bought it thinking it would match up to his RZR for his wife and quickly realized it wasn't what he was looking for. But, for my oldest son, its a perfect fit with a few changes.

Now, I notice that the 2017 Ace 370 has dual a-arms meaning that all of the 1.5" A-arms wont work and those seem to be necessary to get larger tires on the Ace to stop them from rubbing.

I'm curious .. how are people addressing this on the 2017 right now? Or is everyone waiting for a company to come up with a solution?

I don't want to go too big to start. I want a bit more stability, so I'm thinking 28" tires on 14" beadlocks, coupled with 1.5-2" wheel spacers at all 4 corners. If necessary I would do a 1 or 2" puck lift to get it the height, but it looks like people were able to get 28"s on the older Ace's with the extended a-arms without the need to go taller which would be great of course.

Thanks and let me know what you know =)
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Factory wheel offset

I’m looking at getting new wheels for my 04 Sportmans 400. The new wheels are a 4+3 offset. But I was wondering, what is the factory offset?


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