I have a 2002 Sportsman 6x6 that needs a carb, All I have is a carb from a 2005 Sportsman 6x6. I put in on and it runs like crap. Can I adjust the setting to the 2005 Carb to make it work?

 

Should work since the 500 motor are all the same. Some 500s used a smaller 34mm carb while the H.Os used a 40mm is the only change I know of .

Looks like the 2002 and 2005 6x6 both used a 34mm. 2002 Polaris Sportsman 6x6 ATVs

Are you sure you did not get a 40mm.?

 

I have Part # 3131572, the 2002 calls for Part # 3131387, I was also told that a 2003 Carb was compatible with the 2002, the part # for the 2003 is 3131446. Do you know of any other carb's that is compatible with 2002.

 

Like I said the motor never changed, not sure of Polaris reasoning for so many different part number of the 34mm-CV Mikuni carb but all off them are made to run the Fuji built 500 motor so it should not matter which one you put on it.

I know a guy who blew up his 400 Sportsman(425cc) same motor as the 500 just a different bore and/or stroke. He straight bolted a used 500H.O motor in the SP400 and it ran great using his old 34mm carb and the 500H.O was ment for the 40mm but it still made no differance.

Here is his PM to me.
Thats why I find it odd that your new carb is not working for you it should just be a straight foward swap.

 

Carbs and jetting are basically the same on the 2002 and 2005 carbs. 142.5 main and 40 pilot on both. Was the 2005 carb in good shape,rebuilt,new needle and seat,or did you just throw it on?? If the carb needle and seat are good,float level is ok and jets are clean,you may have to remove the fuel/air mixture block off plug and adjust the mixture screw. This just handles mainly the idle circuit though. Also(can't remember which year model on the carbs) the vacuum and fuel inlets were reversed( fuel inlet was on right hand side,vacuum on the left as you are sitting on the machine looking at the carb) Don't know if this helps. OPT

 

are you talking about the pilot screw?

 

Yes, the pilot screw or fuel/air mixture screw as I call it. OPT

 

Well, Found the problem, but got another one, well, not really. I was told the history about this 6x6 and it a goody.

someone else was working on this before, I was busy with something else, but I did put the carb on today, when i was installing the throttle cable, i noticed it was a little tight, so i backed it all the way off at the handle bars, then adjusted it at 1/8" free play, there was not free play before. works great, but now it has a erratic Idle, goes from 900 to 1300, up and down. I can rule anything out pertaining to the carb, since its brand new. Changed the Spark plug, air cleaner is new, belt is new, choke and throttle is adjusted, but i was thinking it could be the throttle cable because sometimes it will idle fine for a moment, then quickly tap on the throttle and the idle will go down. so much that it will almost cut off. Only other think i can think of is valves or timing, any input?

The history is, I found out it was hit by a IED several years ago, the rider survived. the fram was welded back together, and everything was put back together with spare (used) parts that were laying around. the frame says its a 2002, but its a mix match of different years. the only thing pretty much left from the blast is the engine.

 

Check that the carb is fully in the intake manifold and that there are no cracks or splits,especially around the clamp area. Sounds like you may have some type of air leak? Plus you might want to take of the top cap of the carb and check that the spring hasn't kinked and the carb slide is operating smoothly and the rubber part of the slide is ok. OPT