Polaris Sportsman 500 tuning

Removing a carburetor from a Polaris Sportsman 500 and basic maintenance.
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[@PandBMotorsports]

I just did a carb rebuild on 2000 Polaris Sportsman 500. A lot of the difficult things that need to be done to remove the carb are glossed over in this video. (Most people search for videos because they have never done this before.) Items that would be helpful to video include removal of the choke and throttle cables, getting the ducts out ... As some of the other commenters have noted as a problem, mine would not idle. This seems to be a function of a pilot valve. So, i bought a rebuild kit from Amazon and replaced all the jets and needles, including the pilot valve. The Service Manual (700 pages, as i recall) indicates the initial setting for the pilot screw (valve) but says final adjustment needs to be done with the carb installed and motor running. It is virtually impossible to get at that screw. Maybe there is a small, flexible screwdriver that is available that I don't have, and at the moment mine seems to run OK with the initial bench adjustment. But I have come to the conclusion that Polaris designed this thing wit the idea of maximizing the amount of time it takes to do stuff so the dealers (the ne in my area charges $145/hr) can really reap a profit.

[@TomsTinkeringandAdventures]

Jim Perry well I could have shown every single step, but the video might be 2 hours long. My editing isn’t the best, could likely show some of that stuff and cut it down so I will try a bit harder. There are special screwdrivers for adjusting the pilot screw, they aren’t too much money. Anyway, I hope there was at least a little bit of useful information in the video and I appreciate your feedback.

[@markmorris3415]

Very cool. I’m finally subscribed. Congratulations on your channel getting so many views!

[@TomsTinkeringandAdventures]

Mark Morris hey, nice to see you here!

[@gachaencre2751]

Good videos.

[@TomsTinkeringandAdventures]

Gacha Encore thanks for watching!

[@ShaneZettelmier]

You can come over and do mine. I’ve got a sportsman 700 EFI but it sat for about 3 1/2 years and now the fuel doesn’t seem to be getting to the cylinders. Fuel injectors are like 20 bucks a set but it’s just a pain and then I have to do all the maintenance and tuneup stuff and check the clutch and belt and all of it and I’m dreading it. Lol. I’m in Kentucky so if you’re ever coming by feel free to stop by and fix mine 😂

[@TomsTinkeringandAdventures]

I rode through Kentucky a few years ago, one of my favorite areas. Is the fuel pump working? I worked on one of those a while back, the pump was not putting out enough pressure. Good luck!

[@ShaneZettelmier]

@@TomsTinkeringandAdventures I haven’t gotten that far. We moved to the woods and I had a back injury and I and the mower sat for about three years because in the woods you don’t grow a lawn. So I had people help me push him on the truck and dump them off in the garage when we got here and the mower became the priority so now to pay somebody $45 a week to do it for me and after sitting for three years and being an 18 year old mower it needed a lot of work but I grabbed a battery for the ATV and of course when I put it in the battery box exploded because it’s 18 years old as well. Lol. So I got the new battery box and put that in and it turns over great but it’s not flooding so at that point I figured it’s something between the fuel injectors and the fuel pump that sits in the gas tank I think. I haven’t messed with it since then I just put a battery tender on it and tore apart and rebuilt the mower. I don’t really have anywhere to ride the ATV in this house but we’re moving but I’d still like to get it fixed but I’ve never worked on it before and I have no idea what I’m in for. 😂😂 I started looking at videos on how to do the fuel pump and the injectors and I’m just gonna hope it’s the injectors because they’re $19 in a lot easier to get to but I haven’t gotten that far yet. That’s why I was hoping you’d be driving through town and just do it for me. 😂😂😂

[@TomsTinkeringandAdventures]

@@ShaneZettelmier make it worth my while with some good food and drinks, might be on my way! 😂

[@ShaneZettelmier]

@@TomsTinkeringandAdventures 😂😂 🙌🏼 i’ll start up the grill. 😜

[@berlinvlogs]

HaveAGreatDay

[@TomsTinkeringandAdventures]

You too

[@adamskead8859]

Was hoping to see the carb tuning

[@TomsTinkeringandAdventures]

Adam Skead I got ahead of myself in the video.... it only needed cleaning.

[@davew657]

I was hoping to see the o-ring on the idle adjustment cable where it screws into the carb body. My o-ring was cracked and water got inside, rust built up on the threads and the gold looking metal on the inside under the side cover, video time stamp, 5:29. My adjustment cable broke in half. I got a new one but it came without an o-ring. All i can find is the whole cable on internet searches, no separate o-ring. I have a whole 0-ring kit but none that fit tight. 2013 Sportsman 4x4 HO

[@TomsTinkeringandAdventures]

I hate it when you can’t get a simple little part like that. If you have a hydraulic supply store near you, they usually have a wide variety of O-rings.

[@flyguy68]

Funny guy! But several things. What you tune? Carb overflowing? You fix it? Was it o rings or the tube in fuel bowl? Yes hard to shift cause rpm is too high. But not a bad buy. I have the same one.

[@TomsTinkeringandAdventures]

I really just ended up cleaning the carburetor, it didn’t need much else. I found out after the video about high rpm causing difficulties shifting.

[@flyguy68]

I figured! I had these sportsmans for many years flipping then and I like watching peoples triumphs and defeats!! So many of these out there are perfect to fix and flip!! Good luck. Great videos pal!

[@TomsTinkeringandAdventures]

@@flyguy68 thanks for watching, I’m always on the lookout for deals too!

[@brettthacker5822]

The O- rings was the hole point

[@TomsTinkeringandAdventures]

What o-rings?

[@CortezwithaZ]

9:39 minute mark was an ride.

[@TomsTinkeringandAdventures]

Robert Roy I need to try it in high gear yet!

[@Atomic-l4c]

What is that intake with the runnber boot on it that you removed after the carb? Whats it called? Thanks!

[@TomsTinkeringandAdventures]

The long rubber tube that was behind the carb on the left hand side? That's a clutch duct, or something like that. If I have the wrong item, let me know what part of the video you are asking about. Thanks for watching.

[@dankrauel5827]

Great Vid Tom! I have a 600 sportsman that idles perfect in summer but in winter I need to have choke pulled otherwise it idles down so low it stalls when plowing snow. Would you think its a clean the carb issue or isit normal to have to change the idle setting between seasons? Also, do you think it would go faster wearing a Slayer shirt or is Iron Maiden optimal?

[@TomsTinkeringandAdventures]

Dan Krauel cold weather will have an effect on how it runs, if it seems to be accelerating ok then maybe just bump the idle up a bit for winter use. I think a Slayer shirt may add 3 horsepower.

[@lucada8538]

I have the same exact atv, and it does not idle at all, i have to keep my finger on the throtel so it won't die? I think its the carb, do you have any suggestions?

[@TomsTinkeringandAdventures]

daniel daniel is it running ok with the choke on? If so...yeah, probably carburetor

[@lucada8538]

@@TomsTinkeringandAdventures yes it does run with the choke out, Thank you so much! I'll have it cleaned.

[@liveTwoFish]

Thanks for the video, I have a sportsman and have been trying to hmget the carb running right and I'm getting close but my idle adjuster doesn't change my idle speed at all, any thoughts on that?

[@TomsTinkeringandAdventures]

liveTwoFish can you see if it’s moving the throttle cam (where the cables hook onto the carburetor)? The idle adjuster should push it open as you screw it in.

[@duke792]

What did you remove the choke cable with on carb? I cannot get a wrench in there that turns to break loose. Thanks bud

[@TomsTinkeringandAdventures]

It’s been a bit, but I think it’s a 13 or 14mm? Sometimes it’s a tight fit and you have to use a needle nose pliers.

[@duke792]

@@TomsTinkeringandAdventures ok thanks - I modified a 12mm per some other you tubers but no luck. Dude on eBay sells a 12mm customized socket that apparently cracks it loose fyi

[@TomsTinkeringandAdventures]

@@duke792 ahhh, special tools. I have a bunch of them, can never find the one that I need!

[@johnnybegood428]

J aime

[@TomsTinkeringandAdventures]

Merci beaucoup!

[@ejr4140]

your video said you were gonna tune the carb...and you didint !

[@TomsTinkeringandAdventures]

Ejr it’s been a while, but I think I just removed it and cleaned it. Didn’t have to do anything beyond that. Sorry if I said I was going to do adjustments....

[@aydenlatchman9429]

Do you have an guesstimate on what year??

[@TomsTinkeringandAdventures]

Ayden Latchman hmm, I don’t remember but likely mid 2000’s?

[@ragekid3388]

Hey I got a Polaris sportsman 500 and u just changed the cam shaft and rocker arms and Adjusted the valves to .006 and sometimes it revs up and idles like a champ but sometimes it’s sputters and stalls do you know what it is?

[@TomsTinkeringandAdventures]

Hard to tell without looking at it, I would double check all the vacuum lines, carburetor connections, maybe even look at cleaning the carb and tank in case it is contaminated? Best of luck.

[@ragekid3388]

@@TomsTinkeringandAdventures carburetor is new and it’s running on fresh gas do you think I need to double check the valve clearance or you think it’s something electrical?

[@TomsTinkeringandAdventures]

@@ragekid3388 well if everything worked before you did the cam work, definitely want to go over everything in that area closely. It’s never fun when you try to fix something and then another thing breaks.

[@ragekid3388]

@@TomsTinkeringandAdventures the cam it had before was really worn so I replaced it but like I said after I changed the cam shaft it revs up some times like a champ but out of no where some times it sputters and stalls

[@TomsTinkeringandAdventures]

@@ragekid3388 it’s doubtful that the cam is the issue. Just look at anything and everything that was removed and reinstalled during the work.

[@kaylablake8517]

My polaris sportsman 500 runs half throttle but bogs down at full throttle. It has a couple new fuel lines, oil change, oil filter, new carburetor, new battery new coil and wire, new spark plug and new fuel pump. Idk what's causing it not to run full throttle can u help?

[@TomsTinkeringandAdventures]

Kayla Blake it sure sounds like a fuel delivery problem, but you said you have replaced almost everything. Check for air leaks around the carb boot or air box maybe, double check the fuel flow.

[@kaylablake8517]

@@TomsTinkeringandAdventures my dad and my husband adjusted the fuel screw to where it needs t be I'm not sure what the problem is. Alot of people been saying check the air flow screq on carburetor but cant find it

[@TomsTinkeringandAdventures]

Kayla Blake it could also be jetting, main jet could be the wrong size.

[@kaylablake8517]

@@TomsTinkeringandAdventures then bv what can u do we were hoping to get it running good to take it camping next weekend

[@TomsTinkeringandAdventures]

Kayla Blake if you bought an aftermarket Chinese carburetor, you’re not going to have good luck getting it right.

[@dunnkruger8825]

what year please?

[@TomsTinkeringandAdventures]

Matt Lucas I’m sorry, can’t remember what year this quad was. They probably didn’t change much....

[@jsoutdoorz7390]

That's for not showing and carb adjustments

[@TomsTinkeringandAdventures]

That's what I get for making statements before starting the job, not certain that carb adjustments will be needed. Hopefully you got something of value from the video anyway.

[@chadjohns449]

No video ever say nothing about the vacuum hoses to the carburetor

[@TomsTinkeringandAdventures]

Did I say anything about them? I can't remember! LMAO!!!

[@gabeo9474]

I, like most people I'm guessing, came here in search of technical details. While there isn't anything necessarily wrong with this video, there really isn't any technical information whatsoever-let alone any "tuning" like the title states. I suggest renaming the video to something more fitting.

[@TomsTinkeringandAdventures]

Thanks for the input, will probably do exactly that.

[@godwetrust1436]

Any air fuel mix screws?

[@TomsTinkeringandAdventures]

God We Trust I don’t remember, but it probably has an idle air mixture screw? Most carburetors do. Usually start at 1.5 - 2 full turns out from seated and adjust as required.

[@donavanhiggins9096]

My buddy has a sister four wheeler to this one, exact same. He has a question for you about it. I go to your Toms Tinkering page and click about, then click Contact me. But it doesnt do anything, so is there an email that he can reach you at?

[@TomsTinkeringandAdventures]

I have received emails from there before. I will double check. Otherwise just post questions to the comments, I try to respond quickly.

[@sandersisiah]

Is their anyway I can contact you

[@TomsTinkeringandAdventures]

Cards 75 on my channel page, on the “About “ tab there’s a contact me link.

[@sandersisiah]

Tom's Tinkering and Adventures it’s not giving me an email. You can email me at [e-mail]

[@franklinarguedas4832]

Man, you talk too much, get to the point fast and you will be more productive

[@TomsTinkeringandAdventures]

Franklin Arguedas I get plenty done, but thanks for the feedback.

[@mcrighj]

You talk too damn much.. appreciate the advice, but I didn’t even watch it due to too much talking even when I fast forwarded 5 mins…

[@TomsTinkeringandAdventures]

That’s funny, some people say too much, some say not enough…can’t please them all but thanks for commenting.