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Old 03-21-2011, 09:34 AM
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'98 Sportsman 500 carburetor kit

Hi everyone,
New member here, I just bought a '98 Sportsman 500 that needs some minor work. One of the problems is its leaking gas out of the carburetor, but I can't find a rebuild kit anywhere. I've spent hours searching online but all I can find for the Sportsman are kits for a '94-'95 and '99-'00. I've looked up the OEM Polaris part number for the carburetor and the '99 uses a different number than the '98, but judging by the picture the gaskets look similar in shape to my carb. Does anyone know if the '99-'00 kit will work, or where I can find the correct one?
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Old 03-21-2011, 07:03 PM
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Old 03-21-2011, 07:58 PM
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Here's a link but you probably just need to clean it good.
Good luck!

Carb Rebuild Kit Polaris Scrambler Sportsman 03-0408 - eBay (item 300530461259 end time Mar-27-11 07:21:34 PDT)
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Old 03-21-2011, 08:07 PM
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Oh yeah, "Hit the Gas" is a supporting vendor of this site! If you don't do ebay, Phil can probably fix you up. Send him a PM.
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Old 03-22-2011, 04:24 AM
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Thanks! I just bought one. I saw the kits for the Scrambler but I wasn't sure if they were the same as the Sportsman.

Last edited by rowdyredneck; 03-22-2011 at 04:27 AM.
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Old 03-31-2011, 06:36 PM
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I received the kit the other day, took the carb apart tonight and its the wrong kit. After more exhausting research it turns out this kit fits the '98-'02 Scrambler, and it appears the '02 Sportsman only. I've contacted the seller to arrange a return. I don't blame him for it, as the package even says its supposed to fit mine. I'm at a complete loss as to what to do next...absolutely nobody lists a kit to fit the '98 Sportsman 500. The closest thing I can find is for the '99-'00 models, which looks very similar to mine.

I found the leak at least. On the bottom of the carburetor bowl there is a screw with a tapered end. The gas is leaking past that screw and out through the hole in the bottom of the bowl. In the diagram below, its number 21:



Anyone know exactly what the purpose of that screw is? Only thing I can see it being useful for is to drain the fuel from the carb.
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Old 04-01-2011, 08:38 AM
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That screw is to drain the float bowl only. It may just have some grit under it.

Here is a link to a kit at JetsRus:Jets R Us
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Old 04-01-2011, 08:42 AM
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If you click on the "carburetor" tab and then "rebuild kits" it shows that same kit fits 98-02. You might want to contact them to make sure before ordering. I've done business with them before and they know carbs.
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Old 04-01-2011, 08:55 AM
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Here's the link to Shindy's web site. They confirm the same kit number as Jets R us fits 98-02.
As I said before...most times a good thourough cleaning will cure most carb problems. Good Luck!

[ShindyPro.com] Shindy Products, Inc. : Catalog
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Old 04-01-2011, 09:48 AM
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That Shindy kit is the one I have, part number 03-408. If you look at the application, the only Sportsman 500 it fits is the '02 model, plus it fits all '98-02 Scrambler 500s. Its completely different from my carb; the bowl gasket and most of the other parts are different. I think the only thing that might work out of that kit is the needle and seat, but that won't do much for my problem. I tried tightening the drain screw but I couldn't tighten it anymore. After removing it, it looks like the end is slightly deformed.
I ended up ordering a Moose kit for the '99-'00 model....didn't know what else to do. Judging by the pictures I saw of that kit it appears most or maybe all of the parts are the same as mine, but I won't know for sure till I get it. If all else fails I'll just have to epoxy the drain hole shut. I can't see any reason I'd ever want to use the drain screw anyway. Thanks for the suggestions.

Last edited by rowdyredneck; 04-01-2011 at 09:53 AM.
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