Polaris Outlaw 500, Service Manual, Page: 105 / 202

4.10
FUEL SYSTEM / CARBURETION
Carburetor Cleaning
1. Thoroughly clean the carburetor body, jets, and all
passages with carburetor cleaner or electrical contact
cleaner.
2. If the carburetor is extremely dirty or contaminated with
fuel residue and varnish, soak for short periods only in
carburetor cleaner, and rinse in hot water.
3. Replace the jets if they have a buildup of fuel residue or
bacterial growth that cannot be removed. Even a small
amount of residue will reduce the flow characteristics of the
jet.
4. Verify all passages and jets are unobstructed by spraying
electrical contact cleaner through the passages.
IMPORTANT: Do not use wire or welding tip cleaners
as the orifice size may be altered.
5. Use low pressure air to dry carburetor body and all
components.
Carburetor Inspection
1. Inspect jet needle and needle jet for wear. Look for
discoloration, shiny spots, or an area that looks different
than the rest of the needle. The middle to upper portion of
the needle contacts the needle jet and is the most likely
wear point. If jet needle shows signs of wear replace
both
the needle and needle jet to prevent a rich condition.
TIP: A worn needle jet is difficult to spot. To check, slide
a slightly larger new jet needle into the needle jet and hold
it to a light source. Light will be visible between the needle
and needle jet if it is worn.
2. Inspect the inlet needle tapered surface for any sign of wear
or damage. Be sure the spring loaded pin is free moving and
returns freely when pushed. The inlet needle and seat
should be pressure tested after assembly.
WARNING
Protect eyes from contact with cleaner. Take
appropriate safety measures during these
procedures. Safety glasses and chemical
resistant gloves are required. Should you get
cleaner in your eyes or if you swallow cleaner,
seek medical attention immediately.
Carburetor cleaners can be extremely caustic.
Extended periods of soaking can loosen the
adhesive sealer on the passage drill–way plugs.
Do not soak rubber or plastic components (such
as the vacuum slide diaphragm, needle seat
screen, or O–Rings in caustic cleaning
solutions. Irreparable damage may occur. Do
not use agitator-type carburetor cleaning
equipment. Rubber parts must be cleaned with
mild detergent and hot water only.
Jet Needle
Inspect this area
Needle Jet
Good Condition
Worn, Deposits
Seat
Needle
Wear areas
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