HOW TO - Polaris Sportsman 500 Carburetor Clean Carb Rebuild Kit Gas Fuel Cleaner Repair Kit

We are disassembling, cleaning, rebuilding, and re-assembling a Polaris Sportsman 500 HO Carburetor
Get your Carburetor Rebuild KIT before you start: www.ebay.com/i...
Clutch Puller: www.ebay.com/i...
Flywheel Puller: www.ebay.com/i...
CV Shaft Banding Tool: www.ebay.com/i...
Removing the carburetor: • Polaris Carburetor Rem...
Complete Engine Rebuild:
• Polaris Ranger / RZR /...
Front Boot Kit: amzn.to/36SD7J1
Boot Kit: amzn.to/3iT39y2
Service Kit: amzn.to/35O8FPg
Impeller: amzn.to/2IOVyot
Top End Rebuild: amzn.to/2UNjL0v
Blade Kit: amzn.to/3kSYQ6I
Fuel Pump: amzn.to/3pMoC0i
Quality Brake Pad Link: amzn.to/2Y9qowD
Genuine Belt link: amzn.to/37zLxTY
BossBearing Link: amzn.to/2zD0bNw
All Balls Bearing Link: amzn.to/3ec8S0i
Blade Kit: amzn.to/3nBY5Sh
Also more common repairs with the Polaris check out:
• MOST COMMON - Polaris ...
• HOW TO - Polaris Sport...
• PBR Products Floor Boa...
• REPLACE - Polaris Rang...
Mid Nebraska Motorsports YT
PO Box 23
Central City, NE 68826
VENMO is: @midnemotorsports
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[@daniellekettunen2321]

Thanks to this video today I received my certificate in Carburetors 101 from KZbin University. I’m gonna give myself an A grade, and my wonderful teacher featured in this video (and previous video explaining removal of said carb from wheeler) gets two 👍. I have never taken a carburetor apart before in my life, I am not a mechanic, and the wheeler is now running and not pouring gas everywhere (it was the rubber needle that had a groove in it).

[@williefugate7961]

Just wanted to say thanks for this video! At 47, it helped me rebuild my first carburetor ever on my scrambler 500!

[@emoryzayn2432]

you probably dont give a damn but does anybody know of a way to get back into an instagram account?? I somehow lost my login password. I appreciate any help you can offer me.

[@braylonemanuel925]

@Emory Zayn Instablaster ;)

[@emoryzayn2432]

@Braylon Emanuel i really appreciate your reply. I found the site on google and im in the hacking process now. Looks like it's gonna take a while so I will reply here later when my account password hopefully is recovered.

[@emoryzayn2432]

@Braylon Emanuel It did the trick and I actually got access to my account again. Im so happy! Thank you so much you really help me out !

[@braylonemanuel925]

@Emory Zayn no problem =)

[@richardmcewan1330]

Absolutely the best u tube instruction video I have seen, bar none

[@janinevanboxtel9307]

Clear video and great explanation

[@justken4851]

Very informative, thank you! I'm an old guy ....so I will probably have to play this video five or six times when I'm rebuilding the carb especially for the jets and float! 😅

[@MidNebraskaMotorsports]

Play it as many times as you’d like. Thanks for the comment! Let us know if there is anything we can help with. Check out: kzbin.info/www/bejne/jmGklXmuoK-chck for more tips. And: www.ebay.com/str/midnebraskamotorsports for all your parts.

[@tristonjohnson8820]

Weird this video is 20 mins long but for some reason I watched for an hour 😂

[@MidNebraskaMotorsports]

Love it. You should be able to clean this carb with your eyes closed. Thanks for the watching and the comment!

[@RedIron1066]

Thanks from a fellow Nebraskan! Took my old 500HO out to check some alfalfa last night. Mile from home it died like you shut the key off, but would start & idle fine. Damn e-clip came off the needle, dropping it down and shutting off fuel!

[@MidNebraskaMotorsports]

Oh man. Glad the issue quick! Let us know if there is anything we can do to help in the future: www.ebay.com/str/midnebraskamotorsports

[@Eman-qg7uk]

Great video. Really well done. Clear, quick, concise, informative. Thank you.

[@mikaay25]

Excellent video! Very thorough and clearly explained, as well as demonstrated, and perfect job making sure to explain how the damn thing works and how all parts involved, operate properly! I can tell you've done this shit so many times that you understand it all, inside and out! Subscribed, liked and saved for future use! Now I'm gonna test my own ability to apply the same techniques and procedures you explained in both videos (Carb removal and Carb cleaning) along with the overlap part involving the choke and throttle cables, on and off the atv for demo. Thanks and great job!

[@jasonkeith674]

Man I’m glad I came across this video 🙏 Mine is leaking fuel. The hex/torx bolt on bottom was backed out so I tightened it. Didn’t help. I had fuel running up and out the larger breather vent tube that goes down into frame. Taken it off and apart three times now, cleaning and inspecting. Another video showed the “O” ring on float, with the lil tab that helps line it up. I changed that one, it was crusty. Put it all back together and installed. Still leaking out the bottom. Had to take a break. Once I cool off 😡 and get my wits on track, I’ll take it off again and inspect the fuel inlet “O” ring. If that’s not the cause, then I’m stumped. Also, this last time I ran it, it idled sooo high as if the throttle was being pushed. I’ll double check my linkage and the idle screw of course. Also, could that have been caused by fuel just dumping in? Does the large drain plug on the bottom have a gasket or anything? Thanks again for this video!! 🙏🙏🙏

[@whatsit2ya247]

Thanks, very good tutorial! I'm used to motorcycle carbs but these cables had me scratching my brain.

[@MidNebraskaMotorsports]

Happy to help! Thanks for watching and the comment. We have hundreds of videos yet to post. Hit the subscribe button so you are notified when we get them posted. Also check out: www.ebay.com/str/midnebraskamotorsports

[@twinturbohenry]

Amazing clarity! Best video on youtube!

[@hrmthermalimage]

this is a great video I had gas leaking through the overflow and it was gas seeping trough the needle valve seat ring not the needle as it looked great. this was my lucky shot as i took the carb apart 3 times before i decided to replace that seal. Bingo! thank you !!!!!!!!!!!!!!!!!

[@martybauer31]

Great video, thanks so much! I have a scrambler 500 and this looks very close to my carb... the seat with the o-ring you speak of at 11 minutes is slightly too small and so is one of the first things to leak, found a tip from a Facebook group that sizing up this o-ring slightly fixes that fault. I've done it one 3 of my scramblers and it works like a charm!

[@martybauer31]

@@MidNebraskaMotorsports, do a search for the following groups... "polaris scrambler 500", "polaris scrambler/trail blazer III gen and older", and "polaris scrambler, trailblazer, sport fan page". Three great pages with lots of great info!

[@RobertoNelook]

Very well explained. Thanks.

[@MidNebraskaMotorsports]

Thanks Roberto! Happy to help. Thanks for watching and the comment. Let us know if you need anything: www.ebay.com/str/midnebraskamotorsports

[@CR9LUISAU]

Great video! Keep up the good work!

[@garny3766]

Well presented. Few things...1, do you remove and check mixture screw? 2, bowl screws stuck...tap with small hammer or something small and/or slot with hacksaw or sawall blade. 3, when purchasing aftermarket carb kits only thing I end up using is bowl oring and needle and seat. Never do I use the jets or mixture screws. They are close but not Oem.

[@whatsit2ya247]

Good to know! I'm sitting here waiting for my all balls kit, $45 for a o -ring and seat🤬 was the only brand I trust and was going to replace seals and possibly jets but maybe not now, I'll just clean. Main reason for messing with is bowl seal/o-ring leaking.

[@billyburnett18]

good job man i had my throttle get stuck closed some home fixed that now i need to clean the pilot jet from the sounds of it thanks

[@greggmoorman4793]

Awesome video. Truly appreciate your videos

[@janinevanboxtel9307]

I appreciate your thorough video with clear filming and explanations. Do you have another video where you go through installing the parts from the carb kit? I have a few screws left over and two O-rings and do not know where they would go. I replaced the small O-ring on the floater stem and the large one on the drain plug that requires a 17mm wrench to remove.

[@yvonlessard2974]

Hi...Do u have de o-ring number for the floater stem? i didn't find them...thank U

[@seanbrown7659]

Great video! I have a 2006 Scrambler 500 H.O. Do you know if it’s the same carburetor?

[@MidNebraskaMotorsports]

Sorry they aren't the same carbs. Similar cleaning methods though! Thanks for watching and the comment. Let us know if you have any questions or need parts: www.ebay.com/str/midnebraskamotorsports

[@todddowney45]

well explained 'thank you .

[@MidNebraskaMotorsports]

Thanks for watching and the comment Todd. We have hundreds of videos yet to post. Hit the subscribe button so you are notified when we get them posted. Also check out: www.ebay.com/str/midnebraskamotorsports

[@thomaslevey5824]

Great job. One thing every one misses is cleaning the air tube that goes horizontally. It comes out easy and is well worth cleaning for good air mixture. Thanks for your video,

[@adrew1963]

very good video thanks alot.I was wondering why my pilot jet screw is pointy and yours is blunt .I have a 2001 sportsman 500 ho

[@MidNebraskaMotorsports]

Thanks for watching and the comment. That is interesting. I wonder if they did a mid-year change. Polaris is known for that. Keeps people on their toes. ; ) Hope yours is running great!

[@adrew1963]

I had that all wrong I was looking at my idle mixture screw thanks for the video

[@adrew1963]

pilot screw I think my manual calls it

[@mrmotofy]

I got fuel draining dripping tank dry from a hose underneath on R side. I'm guessing the float seat valve is the issue but is there another drain hose that could lead to the issue. Gotta be the carb I'm thinking, looking for a rebuild kit. But a new carb is only $40 sheesh

[@lifeofluke8620]

Any tricks to getting the Phillips head screws holding the carburetor off the ATV. I tried impact screwdriver and it won’t budge. Afraid I’m going to hollow them out.

[@dangerrangerlstc]

Thanks for this video. Don't work on these small engine carbs at all. Had no idea how to remove the carb with the choke and throttle cables attached. Father in laws needs rebuilding, leaking out of that overflow line, even with the tank valve shut off.

[@MidNebraskaMotorsports]

Bummer. Glad this video helps. The choke assembly can be difficult, but we should have a video on the removal process which would include a choke. Make sure you check that out. kzbin.info/www/bejne/r4fPc5qrer-Zh7c Any parts needed check out our ebay store: www.ebay.com/str/midnebraskamotorsports

[@thasocko5737]

What main jet you think I should run? 2000 Polaris sportsman 500 4x4 I’m in Michigan so elevation is in the 0-3000 feet lowest section and it’s cold winter and warm summers you know just kinda looking for all season. One kit I seen has 152.5 and one has 157.5

[@stevenertle2876]

Terrific great job

[@MidNebraskaMotorsports]

Thanks! Catch more on our channel! kzbin.info

[@victorrogers4001]

Loved your video, my question may have nothing to do with the carb. I cleaned the carb as per your video and also set the valves and in the end I had a 1/2 inch long by 1/8 inch ID spring left over, have you any idea where it fits. I have a 2002 sportsman 500. Thanks in advance.

[@MidNebraskaMotorsports]

What the.....you did not follow my steps if you have extra parts ; ). I think you might be talking about the choke plunger spring. Am I correct? Let me know.

[@petekressin9445]

Great video. Nice detail! After I get everything disassembled, it's it OK to soak the whole body of the carb in carb cleaner or will that damage anything like o rings that didn't get removed?

[@MidNebraskaMotorsports]

Pete. I don’t soak the orings in carb cleaner. Even it you did and they don’t dissolve into nothing, it will without a doubt dry and and break down in the future. Hope this answers your questions. Thanks for watching and the comment. We have hundreds of videos yet to post. Hit the subscribe button so you are notified when we get them posted. Also check out: www.ebay.com/str/midnebraskamotorsports

[@duanehaddick4459]

Great video! Do you have a replacement o-ring for the float assembly? My carb rebuild kit did not come with one.

[@MidNebraskaMotorsports]

www.ebay.com/itm/03-05-Polaris-Sportsman-500-Complete-Carb-Kit-Carburetor-Rebuild-Set-/333891265160?mkcid=16&mkevt=1&_trksid=p2349624.m46890.l49286&mkrid=711-127632-2357-0

[@ProTurbo1988]

can you show how to adjust the float

[@ethanhockey6942]

should the plunger be very tight going back into the carb? and also very very hard to get out of the carb?

[@ethanhockey6942]

for the choke cable.

[@MidNebraskaMotorsports]

If it is tight going in it will be stuck open when you pull it the first time using the cable. You might take an emery cloth to it to clean up any build up it. Let us know if you need parts for that machine: ebay.com/str/midnebraskamotorsports

[@cenzo92]

Question: my oil smells like fuel. How can I fix this and what might be causing it? Great video.

[@MidNebraskaMotorsports]

I would replace your needle valve in your carburetor. Carb kit: www.ebay.com/itm/333891265160 Thanks for watching!

[@cenzo92]

Thank you! I have a 2005 Polaris ATP. It appears this carb kit will work for it as well?

[@theautodidacticman_]

One thing you didn’t explain was that top tube that’s bent into a 90* degree like the bottom fuel inlet is. Can you please tell me what hooks up to it? I bought a Polaris basket case so I appreciate any input you may have and thank you in advance!!!

[@cwkie3776]

I have a 2003 polaris sportsman 500. I am fixing a leaky needle and seat. I bought a carb rebuild kit that did not come with a new slide diaphragm. If the old one is in great shape, is it necessary to order a new one? The old one is 20 years old so i am on the fence. Thanks

[@JonathanSherretts]

Should there be a vaccum cap on the carb left side installed , im working on a 2010 sportsman 500 ho that dumps gas and is rough starting will only run with carb and choke cleaner any help would be greatly appreciated. This is one neighbor helping another my neighbor is on ssi 76 and unable to afford a shop so im taking on the job.

[@justinacrea3436]

Great video

[@animal5846]

I put a new carburetter on my 98 scrambler 500 and it runs good but when I turn around and I hit the throttle and bogs down real hard and quits what do I need to do?

[@MidNebraskaMotorsports]

and by new carburetor do you mean OEM or a knock-off. Check out: kzbin.info/www/bejne/oYDZaaGefbqmp5Y

[@robertbenefield1640]

What is that tiny hose for on the bottom I got gas coming out of it

[@MidNebraskaMotorsports]

We explain that on the video, but that is the overflow. Check the video for more details on that. You will need a float needle replaced. Thanks for watching. Let us know if there is anything else you need! www.midnebraskamotorsports.com/

[@Kevin98765]

Thank you so much 👌🏽

[@MidNebraskaMotorsports]

Heck yea Kevin. Thanks for watching and the comment. We have hundreds of videos yet to post. Hit the subscribe button so you are notified when we get them posted. Also check out: www.ebay.com/str/midnebraskamotorsports

[@paulstephens7005]

I own a 2000 Polaris Sportsman 500 RSE and live in Denver (just over 5000 feet above sea level). I'd like to take it hunting at between 8000 to 12000 feet above sea level. What would you suggest my jet sizes be to account for those altitudes?

[@nickchaix7101]

Whats the last year they made this machine carbureted

[@MidNebraskaMotorsports]

I believe 2006. Someone can correct me if I am wrong. Thanks for watching! www.ebay.com/str/midnebraskamotorsports

[@timkjos1495]

I have a 2003 Polaris Sportsman 500 6x6. Are the carbs the same on a Sportsman 500 4x4 as on a 500 6x6?

[@kasonutley4678]

Im ideally ok, can only get the quad up to 30 mph, Possibles ? I’m gonna re clean the carb today. Thanks !

[@andrewsmith7367]

Nice video I have a 2002 polaris 500 ho .I am in the process of replacing the carb. I ran into a problem the choke cable does not seem to want to go back in not sure if there is some trick to it. The choke should just screw back in but won't. Have you had this problem before?

[@janweskamp9997]

Hi. This is a great video about cleaning a carb. I owe a Polaris Sportsamn 700 Twin from 2004. I did take a look on your ebay shop and i want to ask if you make shipments to Germany? Best regards Jan

[@MidNebraskaMotorsports]

Yes, we ship to Germany all the time. Let us know what you need. Also check out: www.midnebraskamotorsports.com/ Thanks for watching. Let us know if there is anything else you need!

[@angrybobking5083]

I accidentally had the acceleration spring for the throttle come off when I was putting the throttle cable back on. How do I put that spring back on the tab??

[@austinfraley6577]

I have 2004 Polaris predator 500 that will start by popping the clutch then once it’s warmed up it will fire right up with the button start. I’m wondering why it won’t start right off the bat if you have any insights that would be amazing.

[@duggiebadd2804]

He said "CLIT" 7:10 😂

[@MidNebraskaMotorsports]

you must be twelve!

[@iddtapthat]

will this rebuild kit work on my 2008 sportsmans 500 ho?

[@MidNebraskaMotorsports]

This kid will not work on the 2008. Let me know if you can't find one. I am sure we have one here. Thanks for watching. Hit the subscribe button as we have a lot more videos coming out on this machine. If you need parts or tools for the job check us out at www.midnebraskamotorsports.com/

[@jsimm4587]

Getting ready to clean a carb on a 2004 ATP 500 will it be the same ? Wish the camera was closer on that video !

[@jsimm4587]

@@MidNebraskaMotorsports I’m a subscriber already thanks for the comment. Waited for a new starter it’s on but someone ordered a new carb and put it on I got it running but haven’t messed with it for a week I’m gonna clean up the old carb and install it back on , the new carb drips the cable is not adjusting correctly and has way too much slack and drips out the overflow. These videos are priceless for the do it yourselfers thanks again .

[@jsimm4587]

@@MidNebraskaMotorsports lol I’m good I think I can get it done . Put my first carb kit in a 66 Chevy truck 6 banger when I was 12 45 years ago !!!! If I lived next door I’d be right over but WV is a long haul !!!!!

[@DavidHernandez-tf7mj]

Quick question I order a piece for a 330 bombardier but instead of getting a 330 bombardier carburetor it came a Polaris carburetor would this carburetor still worked for my 330 bombardier

[@thunderthunder1795]

Is this similar to a 2000/2001 polaris sportsman 500?

[@EarthTrauma]

I have the same carb. The float bowl is horrible. Carb only leaks when it's running.

[@adnanaliferozi2220]

Whats a ression of due to 1st gear and then accelerator bike runing Is jamm....and 2nd gear shift bike run is smooth ....

[@RazorCityDen]

thx bro !

[@jeremylakenes6859]

I have a 454 and the choke seems stuck. I removed the nut. Am I missing something?

[@mathewh3766]

I just bought a brand new carb and installed it. Because old one was in rough condition. It was running fine on the test drive but then began to run quite lean and then I noticed a strong gas smell i took of the seat and noticed gas pouring out of the overflow tube on the bottom of the bowl. My air filter is pretty dirty. Could it be a vacuum issue? or a stuck float? Thanks

[@mathewh3766]

@@MidNebraskaMotorsports thanks i will definitely look into it!

[@rayjungmann]

@@mathewh3766 I have this same problem, I can't see MNM's response. what was the suggestion and did it work? Thank you!

[@stacycantrell2402]

I have a 2008 Polaris Sportsman 500 HO and just rebuilt the carburetor with new jets and all, I’m having a problem with it bogging down at full throttle or when going through a mud hole, what do you think my issue is

[@tonymccall7488]

Did you fix the problem, what resolved it?

[@MrDeticus]

What is the purpose of the small brass tube pressed into the side of the carb running behind the throttle and idle connection?

[@MrDeticus]

@@MidNebraskaMotorsports i skipped ahead to the come removal and watched from there. There was nothing said about what I was asking. Did I miss it?

[@slstarr1026]

Nice video! I just picked up a 04 500 for cheap. What carb rebuild kit would you recommend?

[@claytonosborne313]

Nice video. Only constructive criticism would be to talk slower and zoom in. Hard to see what your talking about.

[@MrAdeuhtyr]

You can slow the video down to whatever speed you want. You can also zoom in all you want. Nothing that our guy needs to do.

[@adolfofireup22]

My carb is always getting clogged, do you recommend anything? Or a better carb?

[@MidNebraskaMotorsports]

Nope, the only reason your carb would get clogged is if there is junk in the fuel tank or you are letting it sit for long period of time. You can put a fuel filter on to help with any debris in the tank, but I would suggest just cleaning it out. Let me know what you find! Thanks for watching.

[@jeffross2639]

I rebuilt the carb and keep getting fuel in my oil. What do you think is going on.

[@jeffpickett508]

Fuel is continuing to flow into float bowl Float is either stuck or you have bad oring in the needle valve. These carbs suck The pilot jet plugs way to easily. Way too small

[@jimspiegel3238]

Can you tell me where the pilot is to be set. Polaris dealership rebuilt my carburetor and it is se at 3 turns counter clockwise. Ideal is way to fast.

[@jeffpickett508]

And you cant readjust with out removing the carb

[@Brokenandsilencedrec]

I had to drill and eazy out my pilot jet. It was stripped, so I think someone had already tried to tear it down...

[@cruza1289]

Me too

[@bonezacklewis]

I have a 02 Sportsman 500 that runs when choke is on, once I push the choke in bike stalls out. Any suggestions before pulling the carb off ?

[@jkcurti]

You should check the module at the throttle switch on the handlebar 1st. There is a little metal contact under the snap on lid that should only make contact when the throttle is suddenly released. Otherwise the information I found indicated there should be a 1mm gap when the throttle is at the idle position. If that doesn't fix it, rebuild or replace the seals etc. in the carburetor.

[@cruza1289]

I have the same problem and it’s not the modual on handle bar it’s apparently a blocked pilot jet

[@scotttopel3971]

Rebuilding a carb without removing and cleaning the emulsion tube that the main jet screws into, is not rebuilding a carburetor