Help with Carb Removal - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum
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post #1 of 18 (permalink) Old 12-18-2010, 12:59 PM Thread Starter
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Help with Carb Removal

I need some help trying to remove the carb. I can not figure out how to take off the throttle and choke cables.

Does anyone have a write up on taking apart the carb. I need to clean this thing out.

Thanks for the help!

07 Foreman 500
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post #2 of 18 (permalink) Old 12-18-2010, 01:05 PM
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For the throttle cable there is a black plastic cover on the side of the carb with one screw holding it on. Remove that, unhook the cable from the throttle linkage and unscrew the cable from the carb.

The choke you just unscrew the plastic nut from the carb and it all pulls out. The carb heater will unplug at the wiring harness. Just follow the wires back to the connector.



2007 420FM (475cc, 27x12x12 Mudbugs) ---------- 1995 300FW (webcamshaft, 350 rear end)
2008 420FE (26x9x12 BearClaws) -------------------
1988 300 (old stock machine, nothing fancy)
2009 420FA (25x8/10x12 BearClaw HTR) ---------
1987 350D (work in progress)

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post #3 of 18 (permalink) Old 12-18-2010, 01:09 PM Thread Starter
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Thanks again Toodeep,

I had it runnung for about an hour this morning. It runs good with the choke on but spits, sputters and will not idle with choke off. It needs a good cleaning

07 Foreman 500

Last edited by jamnjeep; 12-18-2010 at 01:12 PM.
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post #4 of 18 (permalink) Old 12-18-2010, 06:09 PM Thread Starter
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Alright well I was able to get the carb off. I took the bowl off and took out the little and the big jet. cleaned them sprayed them out with cleaner and air. Then sprayed the entire carb with cleaner. It really looked pretty good, not gummy. Then put everything back together. It fired right up and idles good with or with out the choke on. BUT if I touch the throttle it dies. It will only idle. I took the carb back off and bowl off checked everthong I touch made sure it was back together right. Hooked back up and same thing. What did io do? It would at least rev up before i touched it, now just idles.

HELP Please.

07 Foreman 500

Last edited by jamnjeep; 12-18-2010 at 06:12 PM.
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post #5 of 18 (permalink) Old 12-19-2010, 07:57 AM
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try draining the carb while its on the bike. It will allow some clean gas to get in there and will drain anything out that may be in there as well. Do you have fresh gas in the tank....new spark plug? Keep us updated?

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post #6 of 18 (permalink) Old 12-19-2010, 11:27 AM Thread Starter
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Thanks for the advise. Yea i drained all the old gas out of tank and put fresh gas in. Also i have drained the carb several times. It has a good constant flow coming from drain line. The plug is not a new one but looks really good, I sprayed it off with carb cleaner anyway and also check that it was sparking.

I guess something must still be clogged up in the carb?? Thanks for help

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post #7 of 18 (permalink) Old 12-19-2010, 04:30 PM Thread Starter
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So I took the carb off one more time and cleaned it again. Everthing looks really clean. But same problem, it idles great w/ or w/out choke. But if I touch the throttle (even just a little pressure on it) the engine dies right away. If I try and start it while pushing the throttle it just smokes and will not fire up. Its like its getting to much fuel and no air?? opposite from orginal problem, but I am not for sure?
I think I caused the problem! Because it would at least rev up before I took the carb off. But what could I have done wrong during reassembly? All I disassembled was the bowl, float, float valve, big jet and little jet. Is there anything that could have fallen out that I did not notice after removing the items listed? Is there anything that goes in between the needle and main jet?

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post #8 of 18 (permalink) Old 12-19-2010, 05:38 PM
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There is a seat for the throttle needle, it's held in by the main jet. You should be able to look into the carb and see it sticking up slightly.



2007 420FM (475cc, 27x12x12 Mudbugs) ---------- 1995 300FW (webcamshaft, 350 rear end)
2008 420FE (26x9x12 BearClaws) -------------------
1988 300 (old stock machine, nothing fancy)
2009 420FA (25x8/10x12 BearClaw HTR) ---------
1987 350D (work in progress)

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post #9 of 18 (permalink) Old 12-19-2010, 05:55 PM Thread Starter
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odeep:

So I need to remove the main jet and look in there right? The seat should be around the needle? Is it rubber or cooper?

If it was missing do you think it would cause the problems I am having.

Thanks for the help!

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post #10 of 18 (permalink) Old 12-19-2010, 07:27 PM Thread Starter
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Quote:
Originally Posted by toodeep View Post
There is a seat for the throttle needle, it's held in by the main jet. You should be able to look into the carb and see it sticking up slightly.

Took off the main jet and took a look in and all I saw was the needle. There was nothing else in there that could come out.

This must be the issue. I was pretty sure I screwed something up. Going by the local Honda shop tomorrow. I hope this is the issue it seems like the problem.

Thanks alot for all the help, Toodeep! I will post back my results.

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