OldGuyDIY 2003 Polaris 500 ATV Fuel Leak $1 Fix Needle Seat O-Ring #6, NAPA # 730-5017, OEM

Please subscribe if this video saves you time or money.
This video shows how I repaired a 2003 Polaris Sportsman 500 HO ATV that had been sitting for three years with the fuel selector in the on position.
The machine started on the first pull but sounded rough and would die when I pushed the choke in. After shutting the machine off, I noticed gas dripping on the garage floor.
The root cause of the problem was a carb needle seat o-ring that had dried out after 17 years in the machine and 3 years of constant exposure to the alcohol in ethanol.
I did not want to pay $20 for Polaris part # 3130533, my local NAPA did not have part # 730-5017, although their website said they did, so I ended up using a $.79, #6 standard O-ring from the local Ace Hardware.
This failure mode also resulted in fuel in my crankcase oil so the level was high on the oil dipstick and I need to change the oil before running the machine for any length of time.
After installing the #6 O-Ring (5/16' ID, 7/16" OD, 1/16" thickness), there is no evidence of leakage like I had before the repair.
The ATV started on the second pull and stays running with the choke off (pushed all the way in).
Thank you for watching.

[@tomn8tr]

Thank you for sharing your findings. I have the same issue and appreciate you sharing what you have learned.

[@OldGuyDIY]

You are welcome. Good luck.

[@damoncrowfeather4655]

Usually the screws on the bowl are frozen and difficult to remove, but I found if you'll get a pair of those tiny three inch vice grips.. lock it down on the screw, give it a turn, and they'll usually break free.

[@wendella9962]

Wanted to say thanks. My 2010 which had been leaking gas had exactly the same problem. The o-ring to the float needle base, just like yours.

[@OldGuyDIY]

You are welcome. I am glad the video helped you.

[@ssgviper7147]

Good job, going to perform the same task. Called Napa and used your part number, they are getting it in this afternoon.

[@OldGuyDIY]

Great, I am glad it helped you.

[@ericbullard459]

I had the same exact problem with my 96 sportsman 500. This vid was exactly what i needed to fix it!

[@OldGuyDIY]

Great. I am glad the video helped you.

[@e-mansob3577]

Great video!! This fixed my dads fuel leak!! Bought the kit off Ebay for $7.

[@OldGuyDIY]

I am glad the video helped you. Thank you for commenting.

[@toddtheobald3762]

I normally use a impact driver with a screw bit on it to remove the screws. Also keep in mind all petroleum products including Vaseline will eat rubber. Next time use pure silicone paste or spray to lube the O-rings.

[@OldGuyDIY]

Thank you for the comment.

[@briangunderson1983]

Nice job Self. No BS, just good info! Thanks, and ride it like you stole it.

[@OldGuyDIY]

I am glad you liked it. Thank you for commenting.

[@shanebrobst7978]

Helpful video, I have a01 500ho that was leaking fuel Into exhaust manifold. Easy cheap fast fix was Amazon fuel pump for $17.

[@OldGuyDIY]

I am glad you liked it. Thank you for commenting.

[@rcms4d138]

Thanks for the video and tips. Perfect fix for my 500.

[@OldGuyDIY]

You are welcome.

[@mr.c7772]

Worked for me and my 500

[@OldGuyDIY]

Great. I am glad the video helped you.

[@AntonioPereira-sp3on]

Really enjoyed this think this might be a problem in the future found my Polaris scrambler was leaking gas and it’s from the petcock

[@AntonioPereira-sp3on]

Probably going too change the gasket

[@OldGuyDIY]

I am glad you enjoyed it. Thanks for commenting.

[@kylescott4888]

Thanks for sharing. Looks to be my problem!

[@dinostowing712]

Very helpful video.

[@OldGuyDIY]

I am glad you liked it. Thank you for commenting.

[@ontheone9559]

Can you tell me what “book” you found the information from?

[@justinmainville8874]

Does it matter what direction the valve goes in? I know the rubber piece has to be on the outside but I’am not sure if it has to go in a specific way

[@gustavoarroyo1484]

Thank you!

[@OldGuyDIY]

You are welcome.

[@markyoung1416]

Nice video. I tried that o- ring size and it seems to be a little thick. I could not get it to seat right. I tried the oil trick too. I went back to ace and tried a thinner o-ring ( metric not sure what size) and it seems too loose. Leaked very badly. Did you have a hard time seating with that size o-ring? Thanks for the video.

[@OldGuyDIY]

No, it seated fairly easily . I rotated the part with the o-ring on it a little bit as I was installing it and it went right in. Good luck.

[@jimmiller3009]

Great job I have the exact same issue but the hose that goes on the bottom of carb is missing did it have a little filter on it and where does it go

[@OldGuyDIY]

I suspect the filter is just to keep bugs and debris from getting into the carb from the outside atmosphere. The line just allows the overflowing fuel to drop to the ground rather than dripping on a potentially hot engine.

[@alexingram7569]

Will this cause it to only run if you are holding the gas? Mine is a 99 500 sportsman and it leaks when it’s off and only runs when holding the gas.

[@OldGuyDIY]

The machine in the video runs as new after the fix. There is no need to hold anything.

[@andymandybrooks2534]

Which way is the fuel shut valve off to point?

[@DonnyMcDougal]

Did you have trouble getting the carb to to slide back in to the motor?

[@OldGuyDIY]

No, it went back together smoothly.

[@michaelmcnamara6293]

Do you know where I can get a new Drain Line?

[@OldGuyDIY]

eReplacement parts and partzilla have just about every part you will ever want. www.ereplacementparts.com/polaris-a03ch50aa-2003-sportsman-500-parts-c-179712_179713_180105_180114.html

[@josroca]

Was it leaking with the engine running only or all the time?

[@OldGuyDIY]

It was leaking whether running or not. I noticed the problem because there was a spot of fuel beneath the machine in the barn.

[@bradygordon8809]

not sure if you’ll see this but i have a 13 sportsman and it has this same problem but with another problem as well, at about 2500 rpm’s it likes to start choking and wants to die out, would u think that has something to do with the float and the needle not being seated right?

[@OldGuyDIY]

I don't know. It sounds like lack of adequate air flow if it gets too rich at 2500 rpms. Have you checked for a mouse nest in the air cleaner box or mud daubers or debris in the air intake snorkel? Good luck.

[@bradygordon8809]

@@OldGuyDIY no sir it’s all clean, it also has a leak from the carb overflow, it seems like it might be the float

[@OldGuyDIY]

I just suggested the things I would check. I am not a small engine mechanic. If all else fails, you can replace the carb. Good luck.

[@OldGuyDIY]

Another thought. If it is dying out at 2500 RPMs, perhaps the fuel pump has a problem and is not providing enough fuel. Replacing a fuel pump is quick, easy and inexpensive. Good luck.

[@ernestoz6351]

How long it takes you to get it done? Nice video

[@OldGuyDIY]

It took me about an hour and a half, including filming.

[@treysheffield9884]

I got the #6 o ring and it's so hard to put in. Tried ur way and nothing. It seems too thick...2013 sportsman 500 h.o. carb....... something isn't right here. 🤔 does not go on as smooth. Wish u could have video the whole install. Instead u jumped straight into it being in there

[@OldGuyDIY]

I just did the video of my experience. I am sorry it didn't work for you. Have you tried worming the o-ring in hot water or with a hair dryer to make it more pliable. I didn't use either method in this case but have warmed o-rings to ease installation in the past.

[@OldGuyDIY]

You may want to try the NAPA part number 730-5017, as noted in the description.

[@ernestoz6351]

Ok I did changed and run for a little bit and then turned off and I can’t turn it on now

[@OldGuyDIY]

Fuel supply issue?