2002 sportsman 700 carburetor and diff questions - Polaris ATV Forum
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post #1 of 15 (permalink) Old 06-18-2019, 05:19 AM Thread Starter
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2002 sportsman 700 carburetor and diff questions

Thank you in advance. I have a few questions for the group about my machine. I have a 2002 Polaris sportsman 700. How do I find out if this carburetor is the stock carb and where can I purchase a new one? I having a problem at idle and have to keep the machine choked to run. I believe this is a minkuni carb. Any tips on either purchasing a new one or adjusting this one?

Second question is about the front diff. It wouldn’t engage so I drained the fluid out of it to see condition of fluid. Filled it back up and now it engaged but will not disengage. Any advice on this issue?
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post #2 of 15 (permalink) Old 06-18-2019, 06:49 AM
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Stock carb is a:
BST 34 Mikuni
Pilot Jet . . . . . . . . . . . . . 45
Jet Needle . . . . . . . . . . . 4BH41--4
Needle Jet . . . . . . . . . . . P-6
Throttle Valve . . . . . . . . #100
Pilot Screw . . . . . . . . . . 1.5 Turns Out
Pilot Air Jet . . . . . . . . . . 160
Valve Seat . . . . . . . . . . . 1.5
Float Height . . . . . . . . . 14.7mm (.58I)1mm
Fuel Octane (R+M/2) . 87 Non-Oxygenated or
89 Oxygenated (alcohol)

The Chinese copy is all over Ebay for under $50, but you get what you pay for. If it were mine, I would repair the carb that I already have just buying the parts that are needed (if any) - many carbs only need cleaned, not even needing a float bowl gasket - and I do not mean spray clean, most spray carb cleaners are about as good as trying to was tar off a rock by pouring water over it. I use a heated sonic cleaner with a carb specific cleaning agent. The cleaning agent is $70 a gallon, but 10% agent mixed with distilled water, heated to about 150 degrees and the carb immersed in the sonic cleaner for 20 minutes to an hour usually makes it look and perform like new.

I've seen as many new Chinese carbs that needed cleaned right out of the box as I have tires with nails in them that go flat (there's always a few that are OK)

AWD? What kind of oil did you put in and have you tried running it with the new fluid and flushing it a couple times?

Shop Owner and Mechanic with over 50 years experience
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post #3 of 15 (permalink) Old 06-18-2019, 08:08 AM Thread Starter
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I haven’t flushed it one time. So I’m guessing I may need to flush it a few times. Reading more I also need to get the proper fluid. As for the carb I am not sure if this one needs cleaning so I was gonna just start with a new one
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post #4 of 15 (permalink) Old 06-18-2019, 09:58 AM
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If it runs but won't idle it probably just needs the pilot jet cleaned out.
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post #5 of 15 (permalink) Old 06-18-2019, 11:12 AM Thread Starter
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Do you have a picture or a diagram I can reference. I also notice a lot of places that look like they should have vacuum lines and don’t at all. No caps or anything
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post #6 of 15 (permalink) Old 06-18-2019, 11:59 AM
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There is a cap on two ports on the RH side of the carb

#12 in the pic http://parts.polarisind.com/images/6634/6634D07.gif

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post #7 of 15 (permalink) Old 06-18-2019, 07:44 PM Thread Starter
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Does anyone have a diagram of where the vacuum lines and stuf should run off the carb?
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post #8 of 15 (permalink) Old 06-18-2019, 07:46 PM Thread Starter
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Ok sorry didn’t see the previous post
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post #9 of 15 (permalink) Old 06-19-2019, 07:58 AM
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Dont buy a Chinese Carburetor - Clean and rebuild the one you have
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post #10 of 15 (permalink) Old 06-19-2019, 03:49 PM Thread Starter
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This is what the carb looks like on mine.
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