Polaris 1999 Sportsman 400 Service Manual page 188

182 CHA I'TE R S IX
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must move up andreturn without any binding. lft hc
throttle valve asse mbly does not move freely. the
spring may be out of position
withi n
it
and the
cove r. Correct this problem at this time.
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9. Install the mounting plate (Figu re 18) and
tighten the two screws securely.
10. Install the needle valve (Fig u re 31) onto the
float tang.
I I . Inst all the float assembly (B, Figu r e 17) while
aligning the needle valve w ith the needle valve
seat.
12. Install the float pivot pin (A, Figure 17) and
carefu lly tap it in until it is seated (F igu re 32).
Move
the float up and down to ensure free
move-
ment of the needle valve within the seat.
13. Install the O-r ing gasket (Figur e 33 ) into the
float bowl a nd install the
110m
bowl (Figu re 16).
Tighten the screws securely,
14. To assemble the throttle valve/diaphragm as-
sembly, perform the following:
a. Install the E-c1ip (A, Figu re 34 ) onto the jet
needle in the correct location. Refe r to Ta ble
I for standard
Esclip
loca tion .
b. Install the lower ring (B, Figure 34 ) and the
upper ring (Figure 35) .
c. Install the j et needle assembly into the thrott le
valve/diaphragm assemb ly (Figu re 15).
15. Install the spring (F igur e 13) into throttl e
valve/diaphragm assembly to ho ld the jet needle in
place .
16. Install the throttle valve/d ia phrag m assem-
bly (Fig u re 36 ) into the ca rbur etor bod y. Mak e
su re the ou ter pe rimeter of the diaphragm is
sea ted correct ly in the body groove (Fig u re 14).
17. Correctly align the diaphragm lab with the
notch (Figure 37) in the carburetor body.
18. Install the cover (F igure 12) and the screws
and ligh ten securely.
19. Aller the cover is in place, insert a finger into
the carburetor body venturi and push up on the
thrott le valve asse mbly (Figure 38) . The assembly