2005 Polaris Sportsman 400/500 Service Manual, Page 128Get this manual
FUEL SYSTEMCARBURETION
Float arms even
FUEL LEVEL
A fuel level test can be performed on some models if the drain hose fitting is accessibleBe sure to re-attach the bowl drain hose after performing the testA fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetorThe fuel level can be observed with the engine either running or shut off, however, engine must run briefly to allow fuel level to stabilize Bend to adjust float 1Attach clear line to drain fittingBe sure line fits tightly on fittingPosition hose along side of carburetor as shown
NEEDLE AND SEAT LEAKAGE TEST
1Install the float bowlInvert the carburetor and install Mity-Vact (PN 2870975) to the fuel inlet fittingApply PSI pressure to inlet fittingThe needle and seat should hold pressure indefinitelyIf not, inspect needle and seat and seat O-ring1.5 mm .060 Bowl Mating Surface