Yes I plan on using everything. Waiting to hear back from them to see what they say before I open the package

 

Well they were very helpful, he verified that I need the 2001-2002 kit. Previous owner mu at have replaced the carb at some point with one frim a 2001 or 02. Ordered new one and returning the one i have.

 

Is the carb on the machine a Mikuni or a Chinese knock off? The 2001 Sportsman 500 was the first year of the HO series had the same bst40 carb as the 2002,2003,2004,etc..

 

It is a mikuni. All I know is that he said the 2001-2002 used that needle fuel screw, this is the kit he is sending me

 

I don't see bst40 anywhere on it

 

Looks correct. The kit won't say it's for a BST40 carb,just the year model that it fits. Look over this pdf fuel section from the manual. Early model 500s used the BST34 carb.Later model(2001 and up) used the BST40 carb which you should have.https://www.google.com/url?sa=t&rct=...U2gGlaHJWSIlbA

 

I might be doing the cam this weekend if I have time. So you said let the chain and sprocket drop in the case? So I assume it isn't difficult to get them back out of the case? What exactly needs to be done with the valves after new cam is in?

 

Sprocket and chain will be caught by the chain guides,won't drop down far.Once the new cam is in,sprocket and chain timed up and cam blocks are installed,check/ adjust the valves since you're still at tdc.Then install the tensioner(plunger in)install the spring and tensioner bolt. Turn the engine over slowly and the tensioner will self adjust.Button up the rest of the machine,fill with coolant,leave the radiator cap off and bleed the system while at an idle. BEFORE you take the old cam out run the engine at an idle until warm. Drain the oil and remove the line at the oil tank and clean the screen. Replace the line(teflon tape on the threads) and new oil and filter. Pinch off the vent line at the top of the oil tank and run for a couple minutes when the new cam is in. This helps prime the pump quicker.

 

Decided to have my local guy do the cam. He said $50. I've been working doubles so haven't had time. I tried putting the gas tank back in so I could drive it into my truck, I can't get the two tabs in the front of thes tank to line up with the slots. I tried for 30 mins with no luck. Am I missing something? It won't bolt in unless both tabs are in their slots/holes

 

Yes you're missing something just like I did on my first encounter with this style tank when they came out..The older model tanks fit into the frame cutouts.This model tank tabs go BELOW the frame cutouts,not in them. Just angle the tank down and push forward. I felt like a fool fighting with this myself until I figured it out the first time. At least I'm not the only one to do this. Plus for 50 bucks I'd let someone do it to..