Originally Posted by mrmopar | view 174393

I have had this problem for two years now on my 2002 gator 4x2.John Deere will not help you even though they know of this problem.John Deere is never very helpful when you have a problem.That is another story.OK,Here is what my research has turned up.There is a plastic restrictor plug located in the airbox inlet that goes in to the frame.Why would John Deere want to restrict the air intake?I cannot think of any good idea for it.When this restrictor plug falls out of the airbox and it will, it most likely falls in to the frame,That is where I found mine.Without the air restriction the carb runs lean from too much air and thus you need to use the choke just to drive the thing even when warm.Only thanks to tractor and fix it forums like this will you find this out.Our friends here are more helpful than all the John Deere dealers and service people you could talk to.Thanks everyone here for the help!! God Bless you all!!OK,Here is the fix.Most importantly,Do not buy a new $300.00 carb or $50.00 jet kit from Deere,That is what they want you to do.You already paid $6000.00 for a machine you can now barely drive.Assuming you have the Keihin carb, I think Kawasaki used them almost exclusively,Call or go online to Jetsrus out of Marsfield, Mo.They have the jet you need for $14.00 delivered to you.THe keihin carb has the pilot jet located on top of the carb,mine was a size 42.The main jet is in the float bowl as usual.Take off the carb and unscrew and remove the jet.Ther is a separate tube that will fall out when the jet is removed.Be careful to put this back in the same direction it came out.My main jet was a size 88.Order the main jet from jetsrus in a size 92.Description to order is Genuine Keihin slow air jet size 92 (sku-99101-ZF5).Price is $7.29 and $6.98 shipping.Clean the carb with spray carb cleaner and spray in the jet holes and the air bleed small orifice in the carb throat.Put the pilot jet back in the top of the carb, my size 42 does fine. In two days you will get the new 92 main jet,Reinstall the main jet and tube and float bowl.Replace carb and throw away the air resrictor plug you found in the airbox inlet. You have now rejetted and fixed the lean mixture problem.Start up the Gator with the choke, let warm up for 1 minute, put it in gear, Slap your left hand now for wanting to grab the choke again to keep the thing running,Now,Nail the Gas and hang on!!One last thing, Run in the house screaming to you wife that you have a new gator,she will really appreciate it now.

Originally Posted by jxmarco | view 172728

I replaced the fuel pump with an electric pump and fixed my problem, it also clicks loud when you are about to runout of gas.