I have a ’98 or ’99 (it was manufactured in Jan’98) Xplorer 400 2 stroke. I just replaced the head gasket & went to work on the carb. I bought a rebuild kit for it. It wouldn’t hardly run with the stock size Main Jet (200) & the stock Pilot Jet (35) that came with the kit. I had previously bought a 175 & 185 Main Jet. It does real good with the 175 but I put the 185 back in for fear of running it too lean. I pulled the pilot jet that was in there and it was a 30. I bought a 27.5 pilot jet. I can’t get the thing to idle and it doesn’t runs rough in lower half of the throttle. Half throttle and up it does real well with the 175 or 185 Main Jets. I’ve messed with the "air" screw with no noticeable change. I have also messed with the "idle" screw with the same results. It won’t idle without me giving it some throttle and it runs rough.
Any help would be greatly appreciated. This is our work horse and we need the beast back. FYI, it has never run real good since we got it.
John