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Main carb jets are too small on 2004 and 2005 HPX. Should be .033 not stock .028. Will require enlarging for best performance.

Carb trouble possibly
Utility Vehicles UTV/ATV
Replies 11 Post by PvtMatter

Grandpa don't know if you got your answers or not but here is some info. The fuel shutoff solenoid valve is a normally closed device, that is the plunger is out when the engine is off thus blocking the flow of additional gas. When 12v is applied, starting the engine and in the run position, the plunger is retracted allowing the gas to flow. A defective solenoid fails in the closed position thus potentially cutting off the flow of fuel. I said potentially because in my Gator, the valve was defective but still the engine would run. I found the valve too expensive to replace ($147 or so) so I removed it and replaced it with a plug. I personally am comfortable using the key to shut off the engine.

On another subject the 2004 and 2005 Gators have EPA mandated main jets, in the bowl, way too small thus depriving the engine of the necessary fuel for optimum performance (stumbles at full accelerator pressing). A solution is to increase the diameter of the jets from .023 to .033. You will have to do this yourself as the dealers will not perform the service.

gator won t shut off
Utility Vehicles UTV/ATV
Replies 18 Post by PvtMatter

Thanks kt. Mystery solved with a trip to the dealer. My HPX has a cab. The bottom support for the windshield must be removed to access the radiator and brake master cylinder. Duh! There was no apparent way to raise the hood with the windshield closed and locked.

Where did they hide the coolant fill cap
Utility Vehicles UTV/ATV
Replies 3 Post by PvtMatter