Polaris Sportsman 500 runs rough with airbox on/Runs good with airbox off! Find out why!

Do you have a sportsman that runs good with the airbox off? But when installing the airbox..It doesn't run? I show you what to look for.

[@thefix6338]

Dude. You just saved me so much extra headaches. I did the whole carb rebuild, fuel pump, valve / cam check etc. and couldn't figure out what the hell was going on. I've never ran into this bogging issue with a sportsman without it being a fuel related issue. You're the man and thank you so much for this video. 🤙

[@danelldecker3696]

I have been struggling with the carburetor on a 425 magnum and I believe you gave me the answer I was looking for. Always nice information on your channel

[@georgehuffert1800]

I hag a similar problem on a 98 magnum it was a broken filter stand

[@danelldecker3696]

@@georgehuffert1800 This poor thing I’ve been working on was definitely rode hard and tore up. The thing that really baffled me for a minute was the decompression spring, it was there and appeared to be doing its thing but turns out it was shot. Chased that little gremlin for a couple of days.

[@ambermosier3175]

Bought an aftermarket carb for next to nothing.... couldn't dial it in to run right... only with the box off, no air filter, nothing. But I watched some of your vids and bolted the air box tight it runs smooth now...

[@smallgaragehustle]

Having a good sealed up air box is imperative for proper tuning as the resistance ensures the Venturi effect delivers the right amount of fuel. As for the OE carb issues, it’s more productive to swap out the carb with an aftermarket one. HO and Non-HO carbs are inexpensive and plentiful online. When a non-HO needs a cam replacement, I change the cam, carb and intake manifold to the HO model for a little more power.

[@TitaniummanGarage]

The only downfall with the swap is the H.O. had a bigger exhaust pipe. There's a chance the pipe can get really hot. I've done the swap already. didn't notice much of a difference.

[@TitaniummanGarage]

I had put 2 carbs on. a clean oem carb and a aftermarket carb. I got better results from the OEM carb.

[@smallgaragehustle]

@@TitaniummanGarage typically every Polaris I get has a bad carb from sitting, so I replace them instead of rebuilding them. HO conversion was done to see what it was all about, buyer specifically wanted a HO model and I was able to advertise it as such. A well tuned carb will run the best, OE or aftermarket.

[@davebean2886]

What mystery! One might think that a leaky air box would be more like running with the box off? I have a 1999 Polaris Sportsman 500 that was running fine, but has started major loss of power when apply gas, especially up an incline. Changed the air filter and plug - didn't help. Have some seafoam in the gas thinking trying the spray in the carb. Apply the choke when losing power does not help and may make worse. But just for fun - will try running without the air filter box for a short distance. Love the easy tests that can help give info on the problem.

[@TitaniummanGarage]

It could be a bad camshaft. Those years are known for bad cams.

[@alexi8661]

@@TitaniummanGaragewhat years had that issue? Does the 2001 have it.?

[@invertedmirrorimageimi9480]

you ever figure your sportsman? mine is a 96 same issue, major loss of power when goosing it... lurches to a stop if you let off gas quick

[@davebean2886]

​@@invertedmirrorimageimi9480no never fixed issue with my sportsman and does not run at all now. Hoping to take it back to the person I bought it from to see if can fix for a price or buy for parts.

[@deadwood3764]

QUESTION: How many turns on air fuel mixture screw under carb do you usually set?Thanks enjoy the content.

[@TitaniummanGarage]

2 And a half...give or take.

[@redrider533]

Sorry but I don’t see how your video solved a thing. I understand a China carb not working but then I didn’t hear if it previously worked and then started acting up. Then you swap an OEM carb on and same problem so that ruled out a bad China carb. Then you install an air box from a different model year and it runs better. That may have solved the problem for whatever reason but it’s by no means a fix. If the engine ran better with air box removed that means the engine was getting more air. With airbox on the air was restricted and air was decreased so the engine had more fuel that it didn’t like. Typically the carb can handle the air mixture with box in or out when everything else is properly working. So this tells me there’s a different issue. These carbs work off vacuum and pressure differences in front and behind the carb. A worn motor wouldn’t have the same vacuum as a healthy motor . So there’s one avenue to explore. The other avenue is any vacuum lines or or ports on the carb not connected properly. Some of those China carbs have a vent on the top diaphragm cover that is usually shipped with a cap over it. That actually needs vented to atmosphere. The OEM carb doesn’t have that as the port is on the side but still is just a vent. Another issue with these Polaris motors 500s, 600s 700s and 800s is the black rubber intake boot. They will crack with age or leak between the head and boot. This will suck air between the carb and head and cause the lean condition and a vacuum problem. So again we don’t really know the issue here

[@rkreptiles7847]

How do I contact you? Do you accept phone calls? I have a question, first four wheeler and I could use some guidance. Wheeler sat for a long time, would run but shut off when you let off throttle. I replaced the whole carb, put it all back together, got it to fire up and idle, but doesn’t have the power it should when hitting the throttle.. it had plenty of power prior to carb replacement so I don’t think it’s cams or anything like that. Get back to me when you can, trying to get this thing ready for the hunting camp! TIA

[@The_Native_wolfAK]

My polaris trail boss 330 2005 has no spark but has lights on. Hasn’t ran since 2021 and been rusting away I wanna get it started

[@joshuapack614]

clean trigger coil

[@brettpowter6010]

Ive got a 509 ranger efi have replaced fuel pump pressure is 38 psi new cam n rockers starts well runs good for about 15 minutes pressure stays up at 38bpsi then seems to flood at above 2500 rpm plugs black new plug n coil then when turned off wont turn like a bad battery new staryer and a n70 600 cca truck battery fitted with new big leafs and earth directly to engine im ready to burn it whats your idea on the problem 1600 hrs on machine

[@TitaniummanGarage]

Do you mean a 500 ranger? If the plug is black its running rich. It also sounds like the decompression ball on the cam is stuck open. was it a aftermarket cam?

[@richardmartin4634]

I been struggling with my 2011 500 HO sportsman been sitting so im thinking a new carburetor after 7 years in my garage 55 hrs on this machine! What's your thoughts bud? Great videos all around i watch all of yours THANKS MAN

[@TitaniummanGarage]

I would try a carb. drain the gas. What's it doing, or not doing?

[@richardmartin4634]

@@TitaniummanGarage the machine was running great about an hour into ploughing snow just started farting sputtering and backfiring I drained the tank took the line off with inline filter and some gas came out not a lot so I have a new pump to mount and new lines to run. Then the carburetor is next. Does that make sense to you and thanks a lot your awesome! Richard

[@TitaniummanGarage]

@@richardmartin4634.That's what I would do. If you see in some of my videos I use a small fuel tank with a hose and run it to the carb. Its actually off my snowblower. I start ever wheeler with it first. Then plug in the fuel pump ect. If it runs good with the small tamk..but bad with the fuel pump and tank hooked up..I immediately know it's either the pump, vacuum and gas lines or the screen in the gas tank is plugged.

[@plebesdearranke7761]

What carb inlet hose did you use?

[@TitaniummanGarage]

1/4 inch fuel line.

[@collinmoses6785]

I have a 1997 Polaris xplorer 500 and it Cuts out at full throttle when riding but when u rev it it doesn’t cut out do u know what that can be.

[@TitaniummanGarage]

It could be your cdi box. Try unplugging the black wire. If it improves, it's your cdi or kill switch.

[@redrider533]

Could also be the clutch slipping and the engine hitting the revv limiter

[@Silent-Lucidity]

The content is excellent, but the camera focus and bouce is awful. 😢

[@TitaniummanGarage]

I know. Sorry. My 10 year old son wanted to film it.

[@kennyphillips8603]

You need a new camera person. I'm getting sick watching all the shaking. Geez

[@TitaniummanGarage]

I let my 10 year old son run the camera. I gave him the tripod. But he wanted to hold the camera.

[@kennyphillips8603]

@TitaniummanGarage then it's OK. I thought it was the other goofus that works with you. Lol

[@williamtoney2599]

Flexible screwdriver……🫣👍