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    polaris sportman 500

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    polaris sportman 500

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    8 views62 pages

    Capitulo 4

    Uploaded by

    Puri Llinares Martinez
    polaris sportman 500

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 62
    CHAPTER 4 FUEL SYSTEM/CARBURETION Jetting Guidelines. cee we ad Jetting Compensation Charts ... 4.4-4.40 Jet Part Numbers . 44p Oiland Fuel Tank Asm. Exploded View, Gen ll... 4.5 Fuel Tank Asm, Exploded View, Magnum . 46 Oil and Fuel Tank Asm. Exploded View, Gen Ill... 4.7 Fuel Tank Asm. Exploded View, Gen IV... 48 Fuel Tank Asm. Exploded View, Sportsman 500 .. 4.9 Fuel Flow Diagrams 4.10 Mikuni VM Carburetor, Exploded View 2441 Carburetor Function .........2.0000es F 24.12 Carburetor Component Functions ..... Peeeene GAB415 Starter System Operation 4.16 Pilot System Operation a 417 Slide Cutaway Operation ... pavawvenne 418) Jet Noedie/Needle Jet Operation 4.19 Main System Operation 4.20 Component Effect vs. Throttle Opening .......... 4.21 Mikuni VM Carburetor System Components 4.22 Mikuni BST 34 Carburetor, Exploded View 423 Mikuni CV Carburetor System Components ...... 4.24 Mikuni CV Carburetor Operation . 4.25-4.27 Magnum Fuel Tank Removal 4.28 Magnum Carburetor Removal ... 4.29 Mikuni CV Carburetor Disassembly 4.30-4.32 Mikuni CV Carburetor Cleaning + 4.33-4.35 Mikuni CV Carburetor Assembly/inspection 4.36-4.38 Mikuni CV Carburetor Installation 439 Mikuni CV Needle and Seat Pressure Test - 4.40 Mikuni CV Float Bow! Draining 441 Fuel Pump Exploded View 443 Fuel Pump Disassembly/inspection/Assembly .... 4.44 Troubleshooting 4.45-4.46 FUEL SYSTEM/CARBURETION 1996 Specifications Jetting Guidelines Changes in altitude and temperature affect air density, which is essentially the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. Carburetors on Polaris ATVs are calibrated for an altitude of 0-000 ft. (0-900 meters) and ambient temperatures between +40 and +80° F (+5° to +26” C). All carburetors must be re-calibrated if operated outside the production ‘temperature and/or altitude range. The main jet installed in production is not correct for all operating conditions. ‘A main jet that is too small will cause a lean operating condition and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in this chapter, or in the Owner's Safety and Maintenance Manual for each model. NOTE: Maximum engine efficiency and horsepower are directly related to proper carburetor settings. The follow- ing charts have been established as a guideline for selecting optimum jetting for varying temperature and altitude conditions. Air screw of fuel screw adjustment will affect mixture from approximately 0 to 1/4 throttle setting and should be adjusted as follows: Air Screw (2 stroke models) Turn the air screw in (clockwise) 1/4 tum for each 30° below 60° F. Turn the air screw out (counterclockwise) 1/4 tum for each 30° above 60° F Fuel Screw (4 stroke models) Turn the fuel screw in (clockwise) 1/4 tum for each 30° above 60° F. Turn the fuel screw out (counterclockwise) 4/4 tum for each 30° below 60° F. IMPORTANT: The following guidelines must be followed when establishing a main jet setting 1. Select the lowest anticipated temperature at which the machine will be operated, 2. Determine the lowest approximate altitude at which the machine will be operated, 3. Tracing down and across on the chart, use the intersecting main jet recommendation 4, Clutching changes may also be required for changes in elevation. Refer to clutching charts in Chapter 6 for recommendations. Jetting Compensation for Altitude and Temperature ~ 1896 Models Trail Blazer ‘AMOIENT TEMPERATURE Production Jetting Specifications Gh, [rere | eee | alse | Carburetor Type Mikuni VM30SS cm | m | ve] ao | Manet 190 0) Piotdet 40 re er vw | wo | etNeedle —SDP7-9 oe Needle Jet 0-4 (169) wxzno | as | we | wo | CutAvay — 20 60 580) AirSorew Tun | esse Polaris Industries Inc. 44 5/98 FUEL SYSTEM/CARBURETION 1996 Specifications Jetting Compensation for Altitude and Temperature Trail Boss ‘AMBIENT TEMPERATURE: Production Jetting Specifications Boe [orm mort | orem] ome eee, | sees |-8 8228 | anze’ | Carburetor Type: ~ Mikuni VM30SS wee ssoec a ve |e | (Mandet 145 este PilotJet 40 woos | ve | ve Te pm] vetNeedte §—s0Pr3 janie | gouneon Needle vet 0-4 (169) ‘en vecoaroo | vao | to va [owe] taney 2.0 sy AirScrew 1.0 Tums Out ato : * ‘ Xpress 300 “AMBIENT TEMPERATURE Production Jetting Specifications Ow aarr | sore sorF saree | 0° Hae Carburetor Type Mikuni VM30SS ceo ana = Main Jet 155, ea Pilot Jet 4 same | aca ae Ta TET] vetNeede © s0P73 ence | a. S| Nese vet 0-4 (168) on ena | mo] CutAway 20 eens, AicScrw 1.5 Tuns Out zoe | [eo | seme | 2 - tum nates 1210 314 nen = - shaded zone shoud tap Jat Now one postion (aie Ep) Xplorer 300 AMBIENT TEMPERATURE Production Jetting Specifications: SF [SS [SEE [A | conanotr Type... Mun VMGOSS 0900 190, 170, 1s 148 Malin Jet 195 | Se See oe = [SR weosim Oaren =n tee ey a SI ii wi i stn no 7196 42 - Polaris Industries inc. FUEL SYSTEM/CARBURETION 1996 Specifications Jetting Compensation for Altitude and Temperature ‘Scrambler AMDIENT TEMPERATURE Production Jetting Specifications | cea tow [omvon |wroarr | ame Gr | eee | 18 e200 | moe’ | Carburetor Type ........ Mikuni VM34SS seo le ae SS] Mainvet 250 | oso PiotJet 38 meee pom tm} am pe] settNeedte — 6Fo3 ene | cation Needle Jet 0-6 (480) ea jwiozm0 | mo | m0 ao | we | CUAWay = 18 siete ArSeew —— 1.0Tuns Out cae) = > | (EARLY) AGENT TBPERATURE Production Jetting Specifications Xpress 400 | Sportsman 4x4 | war |aeeae [ewes] gms | mburator Type Mikuni VMB4SS Xplorer 400 soon Zit, ] Mainuet 210 400 6x6 PilotJet_ 30 VetNeedle —e0H29.9 ele l= me | 1% | Nesdie Jet 0-6 (480) | — — Cutaway 18 ee we || Airscew —— 1.0Tuns Out ‘ad ‘uwano | 2 rm is Siem em, | = [= vo | sates zon sot ap Jet Noone poation aie EC) 1 -rminaicsren 12103414 (Late) “ANDIENT TEMPERATURE Production Jetting Specifications Sportsman 4x4 Xplorer/xpress 400 | 92" | SuSE | Bee | tet | Carouretor Type Mikuni Visas 400 6x6 tee soe" | Manet 200 2-900 a0 20 a0 08 Pilot vot 30 | tt JetNeedle ECEYS-3 woe | ae | me Te [omen] Neodle Jet 0-8 (480) sane | io Cutaway 15 eon ce To] us| AiScrew = 1.0 Tums out (eee ane, | = va |e (GE - graded zone shoul dop Jet Noodle one positon (sss E-Cip) 2 -turn ar Seren in 210314 en Polaris industries Inc. 43 5/98 FUEL SYSTEM/CARBURETION 1996 Specifications Jetting Compensation for Altitude and Temperature [Magnum 2x4 ‘AMBIENT TEMPERATURE, Production Jetting Specifications | Magnum 4 x 4 Magnum 6 x 6 a PE | SOB ENE | a4, | Carburetor Type Mikuni BST 34 oon peachy | Cauretor 1D. 427018 conf | me |] MainJet = 140 oan fe Pict Jet 40 wae «(OSS | | | [om | Pieter 60 ‘on c| | etNeedle —5F81-9 ‘ross wee fe [| | me FR) Nester pa | pee =| Thratle Vale #100 zona | mas | ry lot Screw 2.5 Tums | Be, z Pt Se 25 Tums Out ( - shaced zone plo screw in 2 um ‘Sportsman 500 ‘AAAENT TEMPERATURE Production Jetting Specifications on wee a a aaee Carburetor Type ........ Mikuni BST34 : Carburetor 4271018 =) =) | Maindet 1426 PiotJet 4255 Pe ‘ice |__| JetNesde 5076-3 re panes | Throtievave #100 me [ms T] wre] Pictserew 1.5 Tus out shaded zone shout atin jet reese one postion raise Elo), 7/96 44 Polaris Industries Inc. FUEL SYSTEM/CARBURETION 1997 Specifications Jetting Compensation for Altitude and Temperature ‘Sportsman 500 ‘AMBIENT TEMPERATURE Production Jetting Specifications mpkorer s90 Bar [oe | ower] ae cae, [vere | “Se” | saan | Carburetor Type ........ Mikuni BST 34 we | HB | Garouretor 0. 227018 ae) Minder aes ova | urs | was | ws | wo | MMatAidet 160 Mines | 06a) JetNeedie 5078-3, irs + Noodle Jet Pat dmsee | “| “8 7] Throtte vave 100 t - PiotSoww 20 zuore | | wo [SSMeaa) a ( --shaded zone pict screw in 2 ten ‘Scrambler 500 /AWBIENT TEMPERATURE Production Jetting Specifications id “ele | Mew | Carburetor Type Mikuni BST 34 bd “ Koon | Carburetor 1.0, 42PLO1B a) Em] Mande 125 exon Pilot Jet 425 Pilot iret 160 ame | doom | | |" | setNecdie S078 ‘ere 5 i NeedeJet PS geosaien | S| "ie Throtle Valve #100 7 Plot Screw 2.0 zaam | ws | ve [SENOS] ter ce . shade zone pict row in 2 ter. Polaris Industries Inc. 4.4c 10/96 FUEL SYSTEM/CARBURETION 1998 Specifications 1998 TRAIL BOSS W9BAA25C (Engine - EC-25PFE-10) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor, Mikuni VM30SS Main Jet - 145. Pilot Jet - 40 Float Level - Float arm parallel with bowl gasket surface (Page 4.22) Jet Needle - 5DP7-3 Needle Jet - 0-4 (169) AirScrew-1 Tum Cutaway-2.0 Needle Seat - 2.5 Flywheel Marking: FF45 CDI Marking: CU2167 Alternator Output: 150 Watts Ignition Timing: 25° BTDC @ 3000 RPM (+ 3°) Spark Plug: BR8ES Gap: 028 (.7mm) Operating RPM: 6000 (+ 200) Idle RPM: 700 (+ 100) Turn out (counterclockwise) one quarter turn for each 30 degrees above 60 degrees F. Observe the following altitude recommendations and set up the vehicle accordingly. “Alitude "AMBIENT Below OF Ot040 | +40°10480°F | +80°F & Above TEMPERATURE | (Below-18°C) | (18°C t0+5°C) | (+5°C to +26°C) | (426°C & Above) Meters 0-900 170 155 145 135 (Feet) (0-3000) 900-1800 155 145) 135 125 (3000-6000) 1800-2700 140 130 120 15 (6000-9000) 2700-3700 730 120 710 100) (9000-12000) - Pilot air screw out 1/2- 3/4 turn from lightly seated. Clutching ‘Anituds Shift Clutch Driven Weight Spring Helix Meters 0-900 16 BlueiGreen 22 (Feet) {0-3000) 300-1800 16 Biue/Green aA (3000-6000) 1800-2700 16 Mod Blue/Green 22 (6000-9000) 2700-3700 16 Mod Blue/Green 22 (9000-12000) 5/98 4.40 Polaris Industries Inc. FUEL SYSTEM/CARBURETION 1998 Specifications 1998 TRAIL BLAZER W9BBA25C (Engine - EC-25PFE-11) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor VM30SS Main Jet- 130 Pilot Jet - 40 oat Level — Float arm parallel with bow! gasket surface (Page 4.22) Cut Away - 2.0 Air Screw - 1 Turn CCW from Seat* Jet Needle - SDP7-3 Needle Jet - 0-4 (169) Needle Seat - 2.5 Flywheel Marking: FF4S CDI Marking: CU2167 Alternator Output: 150 Watts Ignition Timing: 25° BTOC @ 3000 RPM (+ 3°) Spark Plug: BR8ES Gap: .028 (.7mm) Operating RPM: 5800 (200) Idle RPM: 700 (+ 100) “Tum in (clockwise) one quarter tum for each 30 degrees below 60 degrees F. ‘Tum out (counterclockwise) one quarter turn for each 30 degrees above 60 degrees F. (Observe the following altitude recommendations and set up the vehicle accordingly. Anitude Below OF, +40" t0+80°F | +80°F & Above (Below ~18°C) (45°C to +26°C) | (+26°C & Above) Meters 0-900 150 130 120 (Feet) (0-3000) 900-1800 140) 130 120 110) (3000-6000) 1800-2700 125 420 70 100 (6000-9000) 2700-3700 15 10 700 35 (9000-12000) Tum air screw out 1/2 tur (counterclockwise)Shaded Zone should ‘drop Jet Needle one position to lower jet needle Clutching Altitude Shift ‘Clutch Driven Weight Spring Helix Meters: 0-900 G Blue/Green 22 (Feet) (0-3000) 900-1800 c Blus/Green et (3000-6000) 1800-2700 16 BluelGreen 22 (6000-9000) 2700-3700 6 BiueiGrean a (9000-12000) Polaris Industries Ino. 4.40 - 5198 FUEL SYSTEM/CARBURETION 1998 Specifications XPRESS 300 wssCa28C (Engine - EC-28PFE-02) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor VM30SS Main Jet -155 Pilot Jet - 40 Float Level ~ Float arm parallel with bow! gasket surtace (Page 4.22) Cut Away -2 NickeVAluminum Air Screw - 1.5 Turn CCW from Seat Jet Needle -5DP7-3 Needle Jet - 0-4 (169) Needle Seat - 2.5, Flywheel Marking: FF4574 CDI Marking: CU2513. ‘Alternator Output: 150 Watts, Ignition Timing: 25° BTDC @ 3000 RPM (2°) Spark Plug: BREES Gap: .028 (.7mm) Operating RPM: 5600 (+ 200) Idle RPM: 600 (+ 100) ‘Tum in (clockwise) one quarter tum for each 30 degrees below 60 degrees F. ‘Turn out (counterclockwise) one quarter turn for each 30 degrees above 60 degrees F. Observe the following altitude recommendations and set up the vehicle accordingly. ‘Attitude AMBIENT Below OF, (0° to 40"%F 74°10 780F | +80°F & Above TEMPERATURE | (Below—18°C) | (18°C to +5°C) | (45°C to +26°C) | (+26°C & Above) Meters 0-900 7180 170 155 145 (Feet) (0-300) 900-1800 165 750 140 730 (8000-6000) 1800-2700 150 140 730 120 (6000-9000) 2700-8700 135) 125 115 10 (8000-12000) = Shaded Zone should drop Jet Needle one positon (raise E-Clip) ~ Turn Air Screw in 1/2 to 8/4 Turn Clutching ‘Anitude Shift Clutch Driven Weight Spring Helix Meters 0-800 G Blue/Green 22 (Fest) (0-300) 48GR 300-1800 6 BlueiGreen 2201 (3000-6000) 48GR 24 7800-2700 F Blus/Green 22 (6000-9000) 45GR 2700-3700 F Bius/Green 2 (9000-12000) 45GR 5/98 4.4 Polaris Industries Inc. FUEL SYSTEM/CARBURETION 1998 Specifications XLPORER 300 w98cc28c (Engine - EC-28PFE-02) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor VM30SS Main Jet - 155 Pilot Jet - 40 Float Level — Float arm parallel with bow! gasket surface (Page 4.22) Cut Away -2 Nickel/Aluminum Air Screw - 1.5 Turn CCW from Seat* Jet Needle -5DP7-3 Needle Jet - 0-4 (169) Needle Seat -2.5 Flywheel Marking: FF4574 CDI Marking: CU2513 Alternator Output: 150 Watts Ignition Timing: 25° BTDC @ 3000 RPM (+2°) Spark Plug: BR8ES Gap: .028 (.7mm) Operating RPM: 5600 (# 200) _ Idle RPM: 600 (+ 100) “Turn in (clockwise) one quarter turn for each 30 degrees below 60 degrees F. Turn out (counterclockwise) one quarter turn for each 30 degrees above 60 degrees F. Observe the following altitude recommendations and set up the vehicle accordingly. Altitude "AMBIENT Below oF O1040F | +40°t0 +80°F | 180° & Above TEMPERATURE | (Below -18°C) | (18°C to +5°C) | (+5°C to 426°C) | (+26°C & Above) Meters 0-900 780 770) 155 145 (Feet) (0-300) ‘900-1800 165 150 740 730 (8000-6000) 1800-2700 150 7140) 130 120 (6000-9000) 2700-3700 135 725 115 110 (9000-12000) + Shaded Zone should drop Jet Needle one position (raise E-Clip) ~ Tum Air Serow in 1/2 to 3/4 Turn Clutching Alitude Shit hatch Daven Weight Spring Helix Meters 0-900 G Blue/Green. 22 (Feet) (0-3000) 48GR 900-1800 G Blue/Green 2206 (3000-6000) 48GR a4 1800-2700 F Blue/Green 22 (6000-9000) 45GR 2700-3700 F BiuelGreen 2A (9000-12000) 4SGR Polaris Industries Inc. 4.49 5/98 FUEL SYSTEM/CARBURETION 1998 Specifications 1998 XPLORER 400 wosCC38C (Engine - EC-38PLE-06) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor, Mikuni VM34SS Main Jet- 200 Pilot Jet - 30 Float Level — Float arm parallel with bow! gasket surface (Page 4.22) Jot Needle - ECEY6-3 Needle Jet -0-6 (480) Air Screw - 1.5 Turns Needle Seat -2.5 Flywheel Marking: FF95 CDI Marking: CU2510 ‘Alternator Output: 200 Watts Ignition Timing: 28.5° BTOC @ 3000 RPM («1.5°) Spark Plug: BRBES Gap: .028 (.7mm) (Operating RPM: 5700 (1: 200) Idle RPM: 600 (+: 100) ‘Turn out (counterclockwise) one quarter turn for each 30 degrees above 60 degrees F. Observe the following altitude recommendations and set up the vehicle accordingly. “Aritude "AMBIENT Below OF, Ot040°F | +40°10+80°F | +B0°F & Above TEMPERATURE | (Below-18°C) | (18°C to+5°C) | (+5°C to +26°C) | (+26°C & Above) Meters 0-800 230 220 200 185 (Feet) (0-3000) ‘300-1800 210 200 185 170 (3000-6000) 1800-2700 785 170 165 145; (6000-9000) ‘2700-3700 765) 155 145 130 (9000-12000) + Shaded Zone should drop Jet Needle one position (raise E-Clip) - Turn Air Screw in 1/2 to 3/4 Turn From Standard Setting Clutching ‘Alitude Shit Chuich Daven Weight Spring Helix Meters 0-900 S55 BluelGrean 22 (Feet) (0-3000) 900-1800, 355 BiuelGresn Borat (3000-8000) 1800-2700 Ss Blue/Green en (6000-9000) 2700-3700 Ss Blue/Green 2n (9000-12000) 5/98 4.4h Polaris Industries Inc. FUEL SYSTEM/CARBURETION 1998 Specifications 1998 SPORT 400 W98BA38C (Engine - EC-38PLE-07) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor, Mikuni VM34SS Main Jet - 230 Pilot Jet - 35 Float Level ~ Float arm parallel with bow! gasket surface (Page 4.22) Jet Needle - 6CEYE-3 Needle Jet- 0-6 (480) Air Screw - 1.5 Turns* Needle Seat - 2.5 (Large Diameter) Fiywheel Marking: FFOS CDI Marking: CU2515, Alternator Output: 150 Watts Ignition Timing: 28.5° BTOC @ 8000 RPM (+ 3°) Spark Plug: BRSES Gap: .028 (.7mm) Operating RPM: 5700 (#200) Idle RPM: 600 (+ 100) Observe the following altitude recommendations and set up the vehicle accordingly. Altitude AMBIENT Below 0°F 0° to 40°F +40° to +80°F | +80°F & Above TEMPERATURE | (Below~18°C) | (18°C 10 45°C) | (45°C 10 +26°O) | (+26°C & Above) Meiers 0-200 270 250 230 210 (Feet) (0-300) ASerew Stun | ArScrew 10Tum | AiScrew1STum | AlScrew 1.5Tum 900-1800 250 230 210 795, (3000-6000) Air Screw 6 Turn Air Screw 1.0Tum | Air Screw 1.5 Tum | Air Screw 1.75 Turn 1800-2700 220 210 195 VW75 (6000-9000) Air Screw 1.5 Turn Air Screw 1.5 Tum | Air Screw 1.75 Tum | Air Screw 1.75 Tum 2700-3700 200 190 175 160 (9000-12000) Air Screw 1.5 Tum | Al Screw 1.75 Turn _| Air Screw 1.75 Tum | Air Sorew 1.75 Tum - Tur Air Screw out 1/4 turn Clutching Altitude: ‘Shift Clutch Driven Weight Spring Helix Meters 0-900 S-55 White 22 (Feet) (0-3000) 900-1800 8-55 ‘White: 2/2 of 2/1 (3000-6000) 1800-2700 s ‘White at (6000-9000) 2700-3700 Sorc ‘White an (9000-12000) Polaris Industries inc. 4.41 5/98 FUEL SYSTEM/CARBURETION 1998 Specifications 1998 Scrambler 400 W98BC38C (Engine - EC38PLE-09) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor VM34SS Main Jet - 280 Pilot Jet - 35 Float Level — Float arm paralle! with bow! gasket surface (Page 4.22) Cut Away - 1.5 Nickel/Aluminum Air Screw - 1.5 Turn CCW from Seat” Jet Needle - BCEY6-3 Needle Jet - 0-6 (480) Needle Seat - 2.5 (Large Diameter) Flywheel Marking: FF95 CDI Marking: CU2515 Alternator Output: 150 Watts Ignition Timing: 28.5° BTDC @ 3000 RPM (#:3°) Spark Plug: BR8ES Gap: 028 (.7mm) Operating RPM: 5700 (+ 200) Idle RPM: 600 (+ 100) “Tum in (clockwise) one quarter turn for each 30° below 60° F. Turn out (counterclockwise) one quarter turn for each 30° above 60° F. “Anitude "AMBIENT Below OF Oto40F | +40" 10-80 | +80°F & Above TEMPERATURE | (Below~18°C) | (18°C to +5°C) | (+5°C to +26°C) | (426°C & Above) Meters 0-900 BOM 250 MJ 230 MI 210M (Fest) (0-300) O05 AS 1.0 AS 1.5 AS 1.5 AS 300-1800 250 MJ 230 Mi 2i0 MI 195 Nd (3000-6000) OSAS 1.0 AS 1.5AS 1.75.AS 1800-2700 220M POM 195 Md 175 Md (6000-9000) 1.5.AS 1.5 AS 1.75 1.75 AS 2700-3700 200M 790 Ma 175 MI 760 Md (9000-12000) 1.5 AS 1.75.AS 1.75 AS 1.75 AS MJ - Indicates Main Jet Size AS - Indicates Air Screw Turns out from Lightly Seated Position Clutching “Alitude Shift hutch Driven Weight Spring Helix Meters 0-900 S55 “| White 22. (Feet) (0-300) 900-1800 S55 White Be or (8000-6000) 2 1800-2700 S Write A (6000-9000) 2700-3700 Sore White ai (9000-12000) 5/98 4.4) Polaris Industries inc. FUEL SYSTEM/CARBURETION 1998 Specifications Magnum 2 x 4 W98AA42A (Engine - EH-42PLE-02) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor, Mikuni BST 34 (Marking 42PL01B) Main Jet-140 Pilot Jet- 40 Pilot Screw - 2.5 tums out from lightly seated" vet Needle -5F14-3 Needle Jet - P-9 Float Level 13.0mm (Page 4.37) Needle Seat-1.5 Pilot AirJet- 160 Throttle Valve - #100 Flywheel Marking: FF9502_ CDI Marking: CU2509 ‘Alternator Output: 200 Watts Ignition Timing: 30° BTDC @ 3500 RPM (3°) Spark Plug: BKRSES Gap: .028 (.7mm) Operating RPM: 6000 (200) Idle RPM: 1200 (#: 100) “Tum in (clockwise) one quarter turn for each 30 degrees above 60 degrees F. Observe the following altitude recommendations and set up the vehicle accordingly. ‘Alitude “AMBIENT Below OF Oto 40F | +40°t0+80F | +80 & Above TEMPERATURE | (Below-18°C) | (18°C to 45°C) | (+5°C to +26°C) | (+26°C & Above) Meters 0-300) 750 145 140 135 (Feet) (0-3000) ‘900-1800 145 140 135 130 (3000-6000) 1800-2700 BIS 125 Ws 125 (6000-3000) 2700-3700 1325 7S 1225 175 (9000-12000) «Pilot screw in 1/2 turn from standard setting Clutching Altitude Shift Clutch Driven Weight Spring Helix Meters 0-900 TOM Blue/Green 22 (Feet) (0-3000) 900-1800 ToWH BluelGreen 22or (3000-6000) 24 7800-2700 TOR BluelGreen a (6000-9000) 2700-3700 10RH Blue/Green 24 (9000-12000) Polaris industries Inc. 44k 5/98 FUEL SYSTEM/CARBURETION 1998 Specifications Magnum 4 x 4 W98AC42A (Engine - EH-42PLE-02) ‘SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES Carburetor, Mikuni BST 34 (Marking 42PL01B) Main Jet - 140. Pilot Jet - 40 Jet Needle - 51 Needle Seat - 1.5 Pilot Air Jet - 160 Flywheel Marking: FF9502 Operating RPM: 6000 (#200) CDI Marking: CU2509 Throttle Valve - #100 FOR ALTITUDE AND TEMPERATURE Pilot Screw - 2.5 turns out from lightly seated* F14-3 Needle Jet - P-9 Float Level 13.0mm (Page 4.37) “Tum in (clockwise) one quarter turn for each 80 degrees above 60 degrees F, Observe the following altitude recommendations and set up the vehicle accordingly. Alternator Output: 200 Watts Ignition Timing: 30° BTDC @ 3500 RPM (3°) Spark Plug: BKRSES Gap: .028 (.7mm) Idle RPM: 1200 (100) ‘Alitode “AMBIENT Below OF 1040 | +4010 +B0F | +B0°F & Above TEMPERATURE | (Below~18°C) | (-18°C 10 +5°C) | (+5°C to +26°C) | (+26°C & Above) Meters 0-800 150 145 140 135 (Feet) (0-300) 300-1800 145 140 135 130 (3000-6000) 71800-2700 1875 1325 1275 125 (6000-3000) 2700-3700 1325 1275 1225 175 (9000-12000) = Pilot screw in 1/2 tum Clutching ‘Anmtads Shift Chater Driven Weight Spring Helix Meters 0-900 10M BluelGreen 22 (Feet) (0-3000) ‘900-1800 TOWH BluelGreen 22 or (3000-6000) 24 1800-2700 TORAH Blue/Green 2 (6000-8000) 2700-3700 TORH BhuelGreen aA (9000-12000) 5/98 4Al Polaris industries Inc. FUEL SYSTEM/CARBURETION 1998 Specifications 1998 Scrambler 500 W98BC50A (Engine - EHS0PLE-04) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor BST 40 Main Jet - 155 Pilot Jet - 40 Pilot Screw Setting’ - 2.0 tums out from lightly seated Jet Needle - 6H25-94-3, Needle Jet - ¥-0 Float Level 14.7mm (Page 4.37) Needle Seat-1.5 Pilot AirJet - 1.3 Throttle Valve - #100, Flywheel Marking: FF97 CDI Marking: CU2544 Alternator Output: 250 Watts Ignition Timing: 30° BTDC @ 3500 RPM (+ 1.5°) Spark Plug: BKRSES Gap: 028 (.7mm) Operating RPM: 6500 (200) Idle RPM: 1200 (# 100) “Alttude "AMBIENT Below OF, Oto40F | 40°10 180F | +80°F & Above TEMPERATURE | (Below -18°C) | (18°C 10 +5°C) | (+5°C to +26°C) | (+26°C & Above) Meters 0-900 1675 7160 185 1475 (Feet) (0-3000) 900-1800 160 155 1a75 Ta25 (3000-6000) 7800-2700 1525 175 1425 135 (6000-9000) 2700-3700 145 740) 735 730 (9000-12000) ~Turn Air Serew in 1/2 turn Tum Air Screw out 1/2 turn Clutching ‘Attitude Shift Clutch Driven Weight Spring Helix Meters 0-900 TOWH BlueiGreen vA (Feet) (0-8000) 300-1800 Town BlusiGreen a (3000-6000) 1800-2700 RH Blue/Green A (6000-9000) 2700-3700 TORN Blue/Green aA (9000-12000) Polaris Industries inc. 4.4m 5198 FUEL SYSTEM/CARBURETION 1998 Specifications SPORTSMAN 500 W98CH50A (WSOCH50AB) (Engine - EH-S0PLE-07) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor BST34 (CV) Main Jet - 142.5, Pilot Jet - 42.5 Jet Needle -§D78-3 Needle Jet - P-1 Needle Seat-1.5 Pil Flywheel Marking: FF97 Operating RPM: 6000 (+ 200) lot Air Jet - 160 Pilot Screw" - 2.0 Tums out from lightly seated Float Level 13.0mm (Page 4.37) ‘Throttle Valve - #100 CDI Marking: CU2557 Ignition Timing: 30° BTDC @ 3500 RPM (£1.5°) Alternator Output: 250 Watts Spark Plug: BKRSES — Gap: 028 (.7mm) Idle RPM: 1200 (# 100) “Tum out (counterclockwise) one quarter turn for each 30 degrees below 60 degrees F. Observe the following altitude recommendations and set up the vehicle accordingly. Titude | __ AMBIENT Below OF Po 40F | 0°10 +80F | +O0F & Above TEMPERATURE | (Below-18°C) | (-18°C to +5°C) | (+5°C to +26°C) | (426°C & Above) Meters 0-900 1525 Tas 7425 Ta7S (Feet) (0-3000) 300-1800 as T9258 Ts 730 (3000-8000) 1800-2700 140 135 130 125 (6000-9000) 2700-3700 135 130 125 120 (2000-12000) = Pilot sere in 12 turn Clutching Altitude Shift Clutch: Driven Weight Spring Helix Meters 0-900 TMH Blue/Green 22 (Feet) (0-300) 300-1800 70H Blue/Green 2 (3000-6000) 1800-2700 10 WH Blue/Green 21 (6000-9000) 2700-3700 ToRH Biue/Green a (9000-12000) Models Equipped With EBS Require No Helix Adjustment 5/98 44n Polaris Industries Inc. FUEL SYSTEM/CARBURETION 1998 Specifications 1998 BIG BOSS 500 6X6 W9BAE50A (Engine - EHS0PLE-06) SPECIFICATIONS AND CLUTCHING AND JETTING GUIDELINES FOR ALTITUDE AND TEMPERATURE Carburetor BST34 (CV) Mikuni (42PLO1B) Main Jet - 140 Pilot Jet - 40 Pilot Screw* - 2,0 Turns out from lightly seated Jet Needle - 4033-3 Needle Jet -Q-6 Float Level 13.0mm (Page 4.37) Needle Seat-1.5 Pilot Air Jet - 160 Throttle Valve - #100 Flywheel Marking: FF97 CDI Marking: CU2557 Alternator Output: 250 Watts. Ignition Timing: 30° BTDC @ 3600 RPM (+1.5°) ‘Spark Plug: BKRSES Gap: .028 (.7mm) Operating RPM: 6000 (#200) _ Idle RPM: 1200 (+: 100) “Tum out (counterclockwise) one quarter turn for each 80 degrees below 60 degrees F. Anttude “AMBIENT Below OF Oto40F | 40°10 480°F | 80°F & Above TEMPERATURE (Below -18°C) | (-18°C to +5°C) | (+5°C to +26°C) | (+26°C & Above) ‘Meters 0-300 150 145 7140 135 (Feet) (0-000) ‘900-1800 145 140 135) 130 (3000-6000) 7800-2700 1375 135 130 1225 (6000-8000) 2700-3700 1325 1275 1225 nS (9000-12000) + Pilot serew in 1/2 tum Clutching ‘Anitude "AMBIENT Shit Clutch Driven TEMPERATURE Weight Spring Helix Meters: 0-900 10MH Blue/Green 22 (Fest) (0-300) ‘300-1800 TOBH Biue/Green 22 (3000-6000) 7800-2700 TOWH Blue/Green BA (6000-9000) 2700-3700 TOR Biue/Green PA (9000-12000) Polaris Industries Inc. 4.40 5/98 FUEL SYSTEM/CARBURETION Jet Part Numbers Pilot Jets Part Numbers - Mikuni VM vet No. Part No. 30 3180381 35 3130066 40 3130067 Main Jet Part Numbers - Mikuni BST Carburetor 45 3130068 112.5 9190554 50 3130069 115 3130555 ee 1175 3130556 Hex Main Jet Part Numbers - Mikuni VM tao Stee 122.5 8130558 vet No, Part No. Hoe” Iaisteee 110 3130105 127.5 3130560 15 3130106 130 3130561 182.5 3130562 120 3130107. 195 3130563 125 3130108 197.5 3130564 140 3130527 130 3130109 1425 3130866 185 3130110 145. 3130567 1475 3190568 140 3130111 Sous st neeS 145 3130112 152.5 3130570 155 3130571 te sisne 187.5 3130572 155 s13014 160 3130115 165 SISONI6 170 3130117 Pilot Jet Part Number - Mikuni BST Carburetor 175 3130118 40.0 3190624 = — 425 3130526 185 3130120 190 s1g01at 195 3130122 200 3130123 210) 8130124 220 3130125 230 3130126 240 3130127 250 3130128 260 3130129 270 3130130 280 3130131 290 3130132 300 3130133 310 3130134 320 3130135 5/98 Polaris industries Inc. FUEL SYSTEM/CARBURETION Oil Tank and Fuel Tank Assembly - Gen Il (Except Magnum) Z\WARNING When working with any part of the fuel system, observe proper safety proce- dures. Gasoline is extremely flam- mable and explosive under certain conditions. Do not smoke or allow open flames or sparks in or near the area where the work is being done. If you get gasoline in your eyes or if you swallow gasoline, see your doctor im- mediately. If you should spill gasoline on your skin or clothing, immediately ‘wash it off with soap and water and change clothing. Never start the en- gine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause Joss of consciousness and death in a short time, Forward a Oil Level Sensor ‘Vent line routed smoothly into center of steering NOTE: When servicing the fue! or oil system, use care to prevent kinking or obstructing vent lines. Polaris Industries inc. 45 7196 FUEL SYSTEM/CARBURETION Fuel Tank Assembly (Magnum) NOTE: When servicing the fuel or oil system, Use care to prevent kinking or obstructing vent lines. Vent line routed smoothly into center of steering post ZX WARNING ‘When working with any part of the fuel system, observe proper safety prove ‘ures. "Gasoline is extremely flam- mable and explosive under certain conditions. Do not smoke or allow ‘open flames or sparks in or near the area where the work is being done. If you get gasoline in your eyes or if you swallow gasoline, see your doctor im- on your skin or clothing, immediately — ti wash it off with soap and water and a change clothing. Never start the en- R, gine or let it run in an enclosed area. Gasoline powered engine exhaust {fumes are poisonous and can cause loss of consciousness and death in a short time. 7/96 46 Polaris Industries Inc. Z\WARNING ‘When working with any part of the fuel system, observe proper safety proce- dures. Gasoline is extremely flam- mable and explosive under certain conditions. Do not smoke or allow ‘open flames or sparks in or near the area where the work is being done. If you get gasoline in your eyes or if you swallow gasoline, see your doctor im- mediately. If you should spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the en- gine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time, Oil Level Sensor FUEL SYSTEM/CARBURETION Oil Tank and Fuel Tank Assembly (Gen III Typical) Vent line routed smoothly into center of steering post Oil Filter Se NOTE: When servicing the fuel or oil system, use care to prevent kinking or obstructing vent lines. Polaris Industries inc. 47 7196 FUEL SYSTEM/CARBURETION Fuel Tank Assembly (Gen IV) Vent line routed smoothly into center of steering post Forward “3 ‘ONLY ar GGT eg “a 7196 48 Polaris Industries inc. FUEL SYSTEM/CARBURETION Fuel Tank Assembly - 500 Models 1997 Xplorer 500, Sportsman 500 Vent line routed smoothly into center of steering post Forward Outlet %@. “2 (Res)” “1 (ON)” iw NW Silver Fitting (short stand pipe) to “Res (2)" on Fuel Gold Fitting (tall stand pipe) Valve to "ON (1) on Fuel Valve Polaris Industries Inc. 49 10/96 FUEL SYSTEM/CARBURETION Fuel Flow Diagrams Fuel System Diagram - 2 Stroke Models Fuel Tank Vent—} Fuel Tank i Fitting Screens 7 Fuel Filter [<—— Fuel Valve Carburetor Vent Carburetor. ~[|-——+} Engine Fuel System Diagram - 4 Stroke Models Fuel Tank Vent Fuel Tank LJ Fitting Screens > Fuel Pump Filter Fuel Valve Carburstr Vo L_____}- carburetor |———+| Engine % 425 Under Headlamp Cover 500 Above Oil Tank 7/98 410 Polaris Industries Inc. Pilot Jets Part Numbers - Mikuni VM FUEL SYSTEM/CARBURETION Mikuni VM Carburetor “iat at Para oo} 30 3130831 35 3730066 70 3130067 Throtle Rtun Spring 45 3130068 50 3130068 - - Jet Needle Retainer S staner Hex Main Jet Part Numbers - Mikuni VM 5 Phinger Jet No. Part No. E-dlip. Spo Teuke 110 3130105, 4 i Ret 15 3130106 Jet Needle ————_ Spring 720 | sra0r07 om ———F Starter = Smee {Galyon sone no08) iby Plnger__y 135; 3130710 ] a [sea mesos 150 3130713 Needle Jet 8 155 3130114 i an 160 3130115 Fue! Infat 165 3190116 Boy Tratle Stop 170 3130017 Sor ng iif 3130118 Float Arm and Pin 180 3130119 185 3130120 be : Se 190 3130721 S Pilot Jet 195 3130122 a 210 3130124 a aaies Float Retainer}, Bowl Gasket 230 3130126 240 3130127 oat fowl 250 3130128 Floats 260 3130128 270 3130130 ; 280, 3130131 oa wp i Bow! Screws 290 3130182 300 3130133 Main Jet Access Cover

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