2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 153Get this manual
CARBURETORSPORTSMAN 500 Carburetor Inspection
1Inspect jet needle and needle jet for wearLook for discoloration, shiny spots, or an area that looks different than the rest of the needleThe middle to upper portion of the needle contacts the needle jet and is the most likely wear pointIf jet needle shows signs of wear replace both the needle and needle jet to prevent rich conditionTIP: worn needle jet is difficult to spotTo check, slide slightly larger new jet needle into the needle jet and hold it to light sourceLight will be visible between the needle and needle jet if it is worndiaphragm should fit properly in the carburetor bodyReplace diaphragm assembly if diaphragm is damaged
Jet Needle
Needle Jet
Inspect this area
Inspect the inlet needle tapered surface for any sign of wear or damageBe sure the spring loaded pin is free moving and returns freely when pushedThe inlet needle and seat should be pressure tested after assemblyGood Condition Worn, DepositsReplace parts in proper orderThe spring seat (B) is stepped and must be placed on TOP of "E" Clip (C)Spacer washer (D) must be installed below the EClipRefer to parts manual for more informationBe sure the tab (E) on outer edge of diaphragm is positioned properly in the carburetor body