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ATV Repair and Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

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Old 12-04-2011, 03:25 PM
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1986 Trail Boss Flooding Issue

Got a 1986 Trail Boss 250 that had been sitting for a long time. Stripped it down. Cleaned the carb. Replaced the spark plug. Compression above 100. Put it back together.

Running the machine, I got a few back fires through the exhaust. Check the air box, had fuel in it. My guess is a bad needle/seat? Kicking myself for not replacing it when I had the carb out.

Whats your take on it? Any other reason why I would have fuel in the intake?
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Old 12-04-2011, 06:01 PM
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Old 12-04-2011, 08:03 PM
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Thanks Bruce. After doing some more reading, I have narrowed it down to a faulty needle/seat. Going to call the local stealership tomorrow to check on prices. I wasn't able to find a 86-88 Trail Boss kit online, but figured the 2601 kit on this page might be the closest match. I'm pretty sure the needle/seat match up, as the OEM part # are the same.

Polaris Carburetor Kits

Last edited by tgillespie; 12-04-2011 at 08:08 PM.
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Old 12-04-2011, 08:07 PM
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And since everyone here is probably ATV junkies, I figure I'd post some photos of the rebuild.

Starting photo


With all the plastic removed and cleaned up a bit


Broken swing arm. Welded back together with some good reinforcement steel.


I had the carb out at this stage. Kicking myself in the butt for not rebuilding here.


Everything back together with a bit of paint.... The only reason I wanted the machine was to cut my shoveling time from 45 minutes to 2.
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