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post #1 of 11 (permalink) Old 11-16-2010, 04:06 PM Thread Starter
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DIY Carb removal ??

Does anyone have a video, diagram, or pointers to remove a carb on a 2002 sportsman 500. Need to clean it. Looks fairly simple, but I would love to have something to fall back on since I HAVE NEVER DONE IT. THANX
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post #2 of 11 (permalink) Old 11-16-2010, 05:41 PM
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it's very simple. you're going to have to take the seat off, side plastics and tank. loosen boot from airbox and to the engine intake. take all hoses off, as well as throttle. pull it out. it's really that simple.

if you do not know of any previous carb work on that machine i would suggest you get a rebuild kit for it before you pull it. it'll only be $20-30 and well worth it.
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post #3 of 11 (permalink) Old 08-18-2014, 03:08 PM
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how do you get the throttle cable and the choke cable off?
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post #4 of 11 (permalink) Old 08-18-2014, 03:09 PM
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off of the carburetor? Photos would help.
thanks
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post #5 of 11 (permalink) Old 08-18-2014, 03:26 PM
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Quote:
Originally Posted by brivy1900 View Post
Does anyone have a video, diagram, or pointers to remove a carb on a 2002 sportsman 500. Need to clean it. Looks fairly simple, but I would love to have something to fall back on since I HAVE NEVER DONE IT. THANX
Download an 02 Sportsman service manual here.

Index of /ORV Manuals/Polaris/Sportsman/2002

Thanks,
Will

2012 Sportsman 400HO - 5,800KM and counting.
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post #6 of 11 (permalink) Old 08-18-2014, 03:42 PM
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Lots of how to video's on you tube

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post #7 of 11 (permalink) Old 08-18-2014, 04:55 PM
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post #8 of 11 (permalink) Old 08-19-2014, 04:28 AM
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The choke cable should just unscrew from the carb, I think it's a 10mm wrench that looses the nut. The throttle cable is removed by taking off the side cover, and carefully slide the cable out with the retaining clip. There are videos on youtube, and the service manual has pretty detailed instructions.
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post #9 of 11 (permalink) Old 08-19-2014, 02:29 PM
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Thanks for the help!!
That did it!!
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post #10 of 11 (permalink) Old 08-19-2014, 08:34 PM
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For those that come to this thread again. Took a shot of the homemade wrench that helps out with the Choke cable removal.
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