Carburetor Carb Rebuild Repair Kit for Polaris Sportsman 500 4x4 DUSE 2002

Carburetor Rebuild Kit Compatible With/Replacement For Polaris Sportsman 500 4x4 DUSE 2002, Sportsman 500 4x4 DUSE HO 2001, Sportsman 500 4x4 HO AA- AC- AE- AG 2004

Key Features

• Comprehensive component set includes gaskets, O-rings, jets, and needle valve assemblies.
• Precision-engineered parts designed to meet original equipment specifications for fuel flow and air mixture.
• High-quality sealing materials resistant to ethanol-blended fuels and engine heat.
• Restores engine performance by addressing internal wear and fuel delivery issues.

Replaces / Cross-Reference Part Numbers

• Replaces components typically found in Mikuni-style carburetors for Polaris 500cc engines.
• Designed to function as a direct replacement for standard carburetor repair hardware.

Compatibility & Fitment

• Polaris Sportsman 500 HO: 2001-2005, 2010-2012
• Polaris Scrambler 500 4x4: 1998-2013
• Polaris ATP 500: 2004-2005
• Polaris Worker 500: 1999-2001
• Fits models equipped with 500cc liquid-cooled engines.

When to Replace

• Engine exhibits lean or rich running conditions (popping, black smoke, or hesitation).
• Visible fuel leakage from the carburetor body or bowl gasket.
• Difficulty starting the engine or inconsistent idle speed.
• Degradation of internal rubber components caused by aging or fuel storage.

Installation Tips

• Clean the carburetor body thoroughly with a dedicated solvent before installing new components.
• Photograph the original assembly during disassembly to ensure correct placement of springs and jets.
• Verify that the float height is adjusted to the manufacturer's specification to prevent flooding.
• Inspect the needle seat for debris to ensure a proper seal.
• Use a soft-tipped screwdriver to avoid damaging brass jets during installation.