2003 Polaris Ranger Sportsman 500 Carb Removal & Install
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- Опубликовано: 14 окт 2024
- A how to on carburetor removal in install on a 2003 Polaris Ranger but should work for most of the Polaris 500/600/700 engines.
Ebay ad to buy www.ebay.com/it...
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Things that might help with a project like this:
OEM Polaris Carb: amzn.to/2LLsYBb
Carb Boot: amzn.to/2R2b5E0
Ranger Fuel Pump: amzn.to/2GU8Wpo
This video contains affiliate links, which means that if you click on one of the product links and buy, I'll receive a small commission.
I’ve never been mechanically minded. Just saved myself a whole lot of money; brought a carb off eBay, watched this vid and installed it myself. Many thanks.👍
Ok, watched this 5 year old video yesterday, went home and replaced my carb. Not only was it step-by-step with the vid, but it went super smoothly and started right up. Thanks, Mossman!!
Glad the old video was helpful.
This has to be one of the better video’s out there showing how the throttle cable and choke cable disconnect. I purchased a new aftermarket carb brand new in the box for my 2002 Sportsman 500 HO on Ebay being I smelled gas leaking from the factory original carburetor for a while and now it won't start but turns over fine and has spark. The price on the replacement new carb was a no brainer. My only hope is that it is as good as the original that I also purchased a inexpensive rebuilt kit for. I am kicking it around whether to rebuild the old one or replace it with the new one like you did. Some people claim only a 0-Ring goes bad in the original carb causing the leak. What is holding me back at present is the fact I read elsewhere where someone replaced the original carb with a aftermarket and he found the jet to be a different size then what Polaris equipped the original carburetor with. Did you notice any difference in your Sportsman 500's performance with the new replacement carb? I didn’t see any brand name on the new replacement carburetor I purchased making me think it is a Chinese Knockoff but it looks exactly like the original on the outside from what I am able to see with my original carb still mounted to the engine. Just curious what your thoughts are and anyone else out there as to which way they went with a similar problem. Either way I will need to make a move soon. Just trying to not have to do the job twice if at all possible.
I was the one that had to swap over the original jet into the new aftermarket carb. I believe this one. I contacted the manufacturer and told them what I found. Not sure they did anything about it or not. After I installed the factory jet it ran awesome. Never had any trouble up until I sold it. You can check the jet size to make sure it's the same as factory. I have tried rebuilding these old Polaris carbs with no luck. That is why I tried a new one. There are other parts in the carb that your cheap rebuild kit won't address. By the time you buy all the parts you really need it gets expensive. I would make sure jet sizes are the same and install the new carb.
mossman381 what I think I am going to do first if there is enough room is flip the carb over with the throttle cable and choke cable still connected and unscrew the bowl, pop the float off and see if that brass piece is loose with the O-Ring. If it is I will take that part out of the kit and replace it with it and then check the needle and seat. While I am at it I will unscrew the jet to see if there is a number stamped on it and put the bowl back on and remount the original Carb. If it works that would be great. If not I will take the original carb off and swap the jet with the new carb jet if they don’t match if there is a number on the jet in the new carb. If there isn’t a number I will swap it anyway while I have it apart so I know I have the correct jet Polaris specifies. Thanks for responding.
It's amazing what we can get on line compared to years ago when you didn't have too many options. Looks great.
+Steve Rob I had to make some changes to this carb to get it to work with my ranger. I will have an update video on that.
Really helped me the carb removal for my 2004 Sportsman 500 6x6 (minor differences; space too tight to remove the intake manifold)! Many thanks!!
Great video, especially the close ups! I found a good set of needle nose pliers work great for tightening the choke "nut" since a wrench cant fit on it
I took my 12mm to a grinder shaved it down and it worked beautifully to loosen that fitting just a tip for anyone that struggling with removal of the 12mm choke cable fittings 👌
Thank you sir! The wonder of modern technology.
Thanks for a precise presentation and for speeding through the mundane parts. ,😂
Thank you very much! Could not figure out how to get that choke or throttle cable off of there.
Glad to help.
Thank you for this video. was at a loss for how to get that choke cable off.
That choke cable is a little tricky.
Thanks……that’s been a great help👍
Damn I love you mossman, every part I've had to replace on my 03 duramax, you've had a video showing me how. I bought a used Polaris xpedition and have to swap out for a new carb and what are the odds, you've got a video on that too!
I have quite a few videos. If you have GM trucks and Polaris machines I have you pretty much covered.
Thank you. I also wasn’t sure how to get the throttle cable off. Got it done. Now I just need to buy a carb.
Exactly what I wanted to see. Excellent instructions.
Mossman381 would please give me more answers on where those clear 2 hose on the carb above .and whT are they for
iv read so much junk on here there is supose to be a check ball built into the cam once its started it never happens again only on start up no valve some thing built in to the cam on these i dont know theres so much junk on the inter web its hard to find any thing thank you again
Hello my friend
I have a Polaris Ranger 500 4x4 that does not work at all. After the examination, I found that the carburetor was overflowing with gasoline. I found the spark plug was flooded with gasoline and black smoke. I do not know the problem, is it from the carburetor or from the incompatibility of the spark with the rise and fall of the garden. please reply
Sounds like your carb is flooding your spark plug. You might have trash in your carb or maybe need a new needle and seat. Your carb could be worn out depending on the hours you have on your machine.
Good vídeo brother. Thanks
Did u mess with the idle or pilot screw at all?
Perfect that's what I needed to see very helpful...thank you .
Good evening I have a 2005 polaris 6x6 ...that needs some work can I interchange parts from a 2003 that my buddy has laying around. Also do you have any websites that maybe helpful...thank you in advance for any help you may have.
Most parts will interchange. A lot of the 4x4 parts are the same as well.
Hi mossman, I finally got the new carburetor on my Polaris thanks to your video help, thanks. It runs good now but only with the choke on, do I need to adjust the cable in or out? I put the gas tank back on like a dumbass before I checked it so it's going to be a bitch to reach in there to adjust, any advice? Thanks man.
I had trouble with this carb and it ended up being the main jet was wrong. I ended up using my original main jet in the new carb. Ran good after that.
Thanks mossman.
My choke cable wont fit in my carburetor. The female end that's on the carb is a different diameter. How do I work around that
Mossman vacum line diagram do you have one or can you vidieo one i have a 2002 500 Ranger old one can not find routing for the vacuum lines havina lot of trouble with this this spark plug is all ways wet and and impossable to start witch tube is for vacuum to the carburator
Have you rebuilt the carb? The top is a vent not vacuum if I remember right.
Where does the first hoses you pulled off go to on the other end???
Those hoses on the top of the carb are just vents. They usually go into a hole in the frame.
Where does the 2 vents with the T go to?? Does it just hang down somewhere??
The ones I have seen they come together as one hose and then go in a hole in the frame. Later ones might go to the air cleaner housing.
Im having problems with mine stalling and not reaponding when i press the gas. The guy that sold it to me installed a new carburator, put new spark plugs and new air filters. Not sure what the problem is but its also not going full speed. Noticed that when its running if i pull the choke it goes a lil faster but still nowhere near where it should be. I put a full tank of gas and a lucas fuel injector cleaner. Do u have any idea what the problem can be. Also do they come with a governor and if so how do i cancel it? Mines is a 2004 ranger 500
You have to watch out for those cheap new carbs. I bought one and had to install the original main jet from my old carb into the new carb because it was to small.
@@mossman381 running alot better today. Sprayed some stuff on the belt and cleaned the spark plug. Gonna change the oil and filter sunday. Thnx for the help
no i have not rebuilt the carb . i bought a new one from Zoom Zoom i here there junk not sure . i was weighting for a cable i have the cable now was going to try the new carb but its so cold here i havent been out side in my garage i read some wair that the chock need vacum from the air filter box i have looked every wair for the carb lines and roughting nothing thought you miht have that but dident see any on your sight eather thank you any help would be great i use it to plow my drive and 82 yr old lady next door
The choke does not need a vacuum line. I bought an aftermarket carb and the main jet was to small. I had to put the main jet from the factory carb in the aftermarket carb but it ran good after. I am not sure if you are saying you tried the new carb or you haven't tried the new carb?? If you have compression and spark and you have wet spark plugs it's your carb dumping too much gas. Your needle and seat is probably wore out. People usually get rid of these older Rangers because they start having problems because they were not serviced. Once you get all the little problems fixed they are very reliable machines. The CDI can go out on these Rangers and you will loose spark. If you aren't burning the fuel you plugs will get wet.
ok im going to try it ill check the main jet first will my drill set for main jets what about this cam its supose to have some kind of relief on start up iv looked at the cam in it i see no signs of real wair and im a X Hd macanic old one at that
There is no compression relief for start up on these Polaris 500 motors.
Great video, thanks for your help!
Thanks that helped me out a lot but now my overflow when it's idling runs just fine when I go to ride drive it gas it comes out the Overflow what could be the problem
Looking good.
did it help with the problem you where having ? Just a knockoff china carb?
+buffalostate1 It started up fine but wouldn't back out of the shop. After a small amount of throttle it would bog down. I had to change the main jet on the carb. They had a 152.5 in the carb and my Ranger calls for a 142.5. After the main jet change it is running great. I will have a video on that shortly.
that works . what do think of the carb for the price . China brand?
+buffalostate1 I think it's a china brand. For the price I think it's ok. Rebuilding a factory carb is going to cost a lot more than $170. It took me awhile to figure out the main jet was the problem. I actually found a factory new carb for really cheap that I am probably going to swap out and leave this carb as a backup.
@@mossman381 where the video that u adjusted the main jets
I'm new to these ATV/XUV's and one thing I'm realizing is that parts are expensive. I'm use to it though, I own a Harley and a Kubota. There all expensive. :)
+wyattoneable A new factory carb for this year Ranger is about $500.
You know those vacuum lines on top of the carb? Where does the third line go to? can it just hang down or does it need to be somewhere?
They aren't vacuum lines they are vent lines. They are suppose to go to the air cleaner housing.
I have a 2000 Polaris 325 Magnum and from what I can tell is that there is a hose that goes from the top of the engine to the air cleaner box. And I do not know where the 3rd hose on top of the carb goes. I am confused.
The other hose (not the fuel hose) that I got going to the carb, is coming from the Fuel Pump. Do I have these hoses on correctly? It seems to be running just fine.
My problem now is that the carburetor is leaking from the drain every time I give it throttle.. ughhh
Thanks for taking the time to reply to my comment!!!
so are you putting it on the polaris
mossman could you please tell me what kind of doors are on the 2003 polaris 6x6 and were i could find a set for mine
Those doors were hard to find even back then. Found them on Ebay. I have since looked for them and can't find them anymore. If you watch Ebay a set might show up.
@@mossman381 thanks for the help
do you no what brand they are and what number they would be
ruclips.net/video/wN6fh7g6N78/видео.html
is this an old video, or did u take the tracks off..???..
+Joshua Anthony The tracks are still on. I did this video awhile ago.
I have an 2001 Polaris sportsman 500 ho and looks exactly like that carburetor.
They should be the same.
@@mossman381 my 1999 500 magnum is the same too
Thanks for the info just replaced my card with the video
Glad to help.
How is the Polaris running now?
+Rick Anderson I had to make some changes to get this carb to work on my Ranger. I will have an update video soon.
What are those 2 clear holes
I believe they are just vent hoses. They ran to the frame.
Well Done
this thing is the most unreliable thing i have ever owned it hit's compreshion and thats it spark plug soked with gass .. 2000 hr on it not a lot i have spent a ton of money on this polaris