Hi, I have a 2004.5 600 v twinn. It is carbed and has the fuel pump outside the tank. One hose goes to the carb and the other goes into the air intake (labeled P on the pump). I have gas leaking by the one into the air intake. I replaced the fuel pump and it seems to do the same thing. I assume that the float on the carb must be sticking and needs a good cleaning, could there be something else wrong? Not sure where to go from here?

 

The "p" at the fuel pump is the vacuum inlet. This hose goes to the right side of the carb.The carb pulls a vacuum on this line,fuel coming from the fuel valve enters at the top of the pump,exits on the lower hose(one with the filter) to the carb. Make sure the hoses are hooked up correctly. If you have a new pump and its still leaking at this connection on the carb,then it's probably a carb problem. A good manual can help. Here's a pdf on the 600. Index of /ORV Manuals/Polaris/Sportsman/2005
Plus here's a video on the Polaris 330 that has basically the same type carb.

 

Thank you for the reply. I figured it had something to do with the vacuum. Just wasn't positive. Hopefully I will get to it in the next few weeks, I have to get the rams for an outrigger and bucket tilt on my old Case 311 tractor loader backhoe. Its not a good weekend out to the woods till you break something.