I cleaned the carb on my Polaris scrambler 500 ho put it all back together and it was leaking fuel out of the overflow, did some research replaced the float needle and seat, got it all back together and it's still doing it!!! I'm by no means a mechanic but i want my quad back any ideas would be greatly appreciated

 

your float/needle valve is stuck open. anything minute from a single grain of sand/grit to a strand of cotton from a cotton swap that you used to clean the carb with to a piece of debris from the fuel could make it stick open. even a new float/needle valve. disassemble the carb again, make sure the needle valve and spring are intact in the proper position. clean that port again, put it back together. before putting the bowl back on, turn the carb up the correct way and manipulate the float up/down to verify the needle moves and reacts with the spring. if it strokes, reassemble the bowl and put it it. not familiar with your quad, but if it's a 4 stroke, check your crankcase oil for gasoline contamination. you don't want to blow up the case. if it's got a lot of gasoline in the oil, change oil.

 

Will do ill go over it again getting really flustered with it

 

one thing these machines will do is teach you patience. we'll get you there. don't get frustrated. you'll learn more about your machine and the way it functions. you'll learn to where if you have problems and you're 6 miles from camp and have tools, you can fix it to get back to camp. trust me....that's happened to me before. i'm thankful for this forum. it's taught me a lot. we'll get you there....soon.

 

you do have an inline fuel filter on this machine, right? if not, it won't take much to spud one in.

 

These BST40 carbs are a problem to keep from leaking. I never did like the change from the old reliable separate floats and float arm on the pre 2000 model 500s. See if this helps on the carb and adjusting the float level. It's from a KTM LC4 but basically the same carb as on the Sportsman and Scrambler. The BST-40 Bible - ADVrider And yes,we had leaking problems with the KTM LC4 carbs too!