How to take a carburetor on a 2003 Polaris 700 / 500 Sportsman apart and rebuild it.

How to take a 2003 Polaris carb apart and inspect it. Gas leaking out of the bottom.

[@paulkelm6550]

Thank you for attempting to show what to do. It might be good to invest in a little tripod or a goose-neck pod so that you can use both hands and clearly show what you are demonstrating. I liked that your explanation was straight forward, but the video could be better. Thank you.

[@donfrommpls778]

Thanks for doing this video! I like how you left things attached, really simplified it.

[@TitaniummanGarage]

Glad I could help

[@Caseusfette]

you have rescued me again, thanks for making these videos!

[@TitaniummanGarage]

Awesome!

[@badfit777]

Inspired by your grinded wrench I went a slightly diff way that worked. Took the round end of the wrench and cut a gap to slide it over wire.

[@TitaniummanGarage]

Yup. I've seen that done. It works better actually.

[@deanduchene4035]

I have a 2004 600. It started back firing and idling rough. I looked at the carb and noticed 1 of the vent tubes is capped and the other is open. Couple years ago it did ran the same way and found a hose had came of the open 1 once putting it back on ran great. Problem is there is no hose anywhere now. Do you know where that hose should be and connected to? Looking at some diagrams some say to hook them together but mine wasn’t that way.

[@razrf]

Exactly what mine was doing. thanks for the video

[@davegalway5981]

Awesome. Thanks!!

[@NytronX]

Good video. Now to decide on the following: - Carb kit: $23-28 or more. - Brand new knockoff carb, drop in ready: $32 Taking the throttle cable off is tricky, and the choke cable is apparently designed to be hard to remove. See comment below. Neither is shown in the service manual either.

[@TitaniummanGarage]

It's not bad if you need pull throttle and choke cable. There is a plastic nut/sometimes metal. Just turn it off and choke come out. Should be the same with throttle.

[@TitaniummanGarage]

Also there is a black cover on the side. Take that off and you should see throttle cable.

[@NytronX]

@@TitaniummanGarage To get the choke cable off, you need to fabricate a tool apparently. See here i.imgur.com/T0IQysG.jpg and here www.polarisatvforums.com/forums/polaris-sportsman/55526-can-t-get-choke-cable-off-2.html So even though a new carb is only a few dollars more than a carb kit, the labor is more to install a new carb. Usually the opposite is the case.

[@TitaniummanGarage]

@@NytronX Thanks, I've only taken one off a Honda rancher. It came off pretty easy. Those new carbs for 38 bucks only last a year I hear.

[@mudslingerlastname228]

I tried the zoom zoom parts carb for my polaris 300 45 dollars... Put it on it dumped fuel right out of the box... Ended up using the top piece off the knockoff spring rubber gasket n needle on the minkuni original and it worked... Cleaned it up with choke n carb cleaner and now working on adjusting the cable .... Cheaper doesnt always mean better deal ... But it was worth a try... I guess ...

[@sandersisiah]

I have a 05 sportsman 700 twin. Im having trouble with the fuel lines and how they run. I have the pulse line going to the crankcase, just unsure about the other two. I have a two way shut off valve not a three. Can you give some clarification? Thx .

[@TitaniummanGarage]

So you don't have the reserve. Just on and off? I made a video on that once. If you look at the fuel pump 3 ports come out. The top goes to the tank or fuel shutoff. The middle to the carb and the bottom (marked with a P) goes to the case

[@quarterpanel]

Thanks for the upload. The needle on mine will slip and disappear inside the slider/diaphragm, when I turn the carb upside down. Is this normal, or should it be fixed to the slider?

[@TitaniummanGarage]

The spring should hold it in place. I would inspect it.

[@quarterpanel]

Thanks for the reply. Makes sense to me. Not sure where the problem is other than possible wear. I have found these parts for this needle assembly. The Spring, Small plastic ring at the "c" clip, flanged plastic ring at the base of the slider and the needle. Ended up ordering a china carb on amazon. Hopefully this fixes my issue.

[@Trigger_32]

What was the 1/4" vinyl tube with the in-line filter on the intake side of the carburetor hooked to? Ive got an 02 700 and mine just runs up the belt intake tube towards the top of the fuel tank, has the plastic 90° elbow on it, like yours, but has never been connected to anything. My fuel pump is getting its vacuum pulse's directly from a port on the head. So Im thinking either this is the original fuel pump driver and it can be capped off, or does the carb need this breather? I cant find anything on it anywhere. Thanks.

[@TitaniummanGarage]

It's a breather for the carb. Not sure why it has a filter. Probably so it deasnt suck in dirt.

[@Trigger_32]

Titaniumman Garage interesting. I was gonna cap it, but I guess I’ll just replace the filter and leave it in place. Thanks.

[@evanwilliams2602]

This maybe a dumb question but when I push the throttle on this sportman 700 the carb slide does not open up? Throttle springs back fine it's just weird the slide doesnt open up sounds like it's working is that normal? This is while it's off not running

[@TitaniummanGarage]

You probably have a bad vacuum diaphragm. It's what pulls the slide up.

[@lynncomeau98]

Does the 500 and 700 have the exact same carb in 2002 2003

[@TitaniummanGarage]

That's a good question. They look similar but the 700 is jetted a different size.

[@JefferysawyDigitalcreator]

The carburetors are only forty dollars

[@485292443]

I've tried 3 after market carbs for my 2002 700 twin. All ran worse than the stock carb that's giving me troubles.

[@rustybaxter9606]

Yeah, the quad community isn't very good at making how to videos. I just got a used 05 polaris 700 and trying to find quality how to videos is hard. Hell, I even bought a top rated polaris maintenance book and that thing sucks.