Carburetor Carb Rebuild Repair Kit for Polaris Sportsman 500 4x4 DUSE 2002
Carburetor rebuild kit components for Polaris Sportsman 500 including float, jets, gaskets, and screws.
Components list for Polaris Sportsman 500 carburetor rebuild kit including diaphragm, float, jets, and gaskets.
Carburetor rebuild kit components with compatibility list for Polaris Sportsman 500 and other ATV models.
Rubber carburetor gasket and diaphragm kit for Polaris Sportsman 500, highlighting high-grade fuel-resistant material.
Carburetor rebuild kit components including brass jets, needles, and screws for Polaris Sportsman 500.
Carburetor rebuild kit components for Polaris Sportsman 500 with engine symptom troubleshooting guide.
Polaris Sportsman 500 carburetor rebuild kit components displayed on a promotional lifestyle graphic.
Mechanic holding a Polaris Sportsman 500 carburetor with rebuild kit components displayed below.
Carburetor rebuild kit components including jets, gaskets, and float for Polaris Sportsman 500 comparison graphic.
Carburetor rebuild kit components for Polaris Sportsman 500 including float, jets, gaskets, and screws.
Components list for Polaris Sportsman 500 carburetor rebuild kit including diaphragm, float, jets, and gaskets.
Carburetor rebuild kit components with compatibility list for Polaris Sportsman 500 and other ATV models.
Rubber carburetor gasket and diaphragm kit for Polaris Sportsman 500, highlighting high-grade fuel-resistant material.
Carburetor rebuild kit components including brass jets, needles, and screws for Polaris Sportsman 500.
Carburetor rebuild kit components for Polaris Sportsman 500 with engine symptom troubleshooting guide.
Polaris Sportsman 500 carburetor rebuild kit components displayed on a promotional lifestyle graphic.
Mechanic holding a Polaris Sportsman 500 carburetor with rebuild kit components displayed below.
Carburetor rebuild kit components including jets, gaskets, and float for Polaris Sportsman 500 comparison graphic.
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Carburetor Carb Rebuild Repair Kit for Polaris Sportsman 500 4x4 DUSE 2002

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Carburetor Rebuild Kit Compatible With/Replacement For Polaris Sportsman 500 4x4 DUSE 2002, Sportsman 500 4x4 DUSE HO 2001, Sportsman 500 4x4 HO AA- AC- AE- AG 2004

Key Features

  • Comprehensive component set includes gaskets, O-rings, jets, and needle valve assemblies.
  • Precision-engineered parts designed to meet original equipment specifications for fuel flow and air mixture.
  • High-quality sealing materials resistant to ethanol-blended fuels and engine heat.
  • Restores engine performance by addressing internal wear and fuel delivery issues.

Replaces / Cross-Reference Part Numbers

  • Replaces components typically found in Mikuni-style carburetors for Polaris 500cc engines.
  • Designed to function as a direct replacement for standard carburetor repair hardware.

Compatibility & Fitment

  • Polaris Sportsman 500 HO: 2001-2005, 2010-2012
  • Polaris Scrambler 500 4x4: 1998-2013
  • Polaris ATP 500: 2004-2005
  • Polaris Worker 500: 1999-2001
  • Fits models equipped with 500cc liquid-cooled engines.

When to Replace

  • Engine exhibits lean or rich running conditions (popping, black smoke, or hesitation).
  • Visible fuel leakage from the carburetor body or bowl gasket.
  • Difficulty starting the engine or inconsistent idle speed.
  • Degradation of internal rubber components caused by aging or fuel storage.

Installation Tips

  • Clean the carburetor body thoroughly with a dedicated solvent before installing new components.
  • Photograph the original assembly during disassembly to ensure correct placement of springs and jets.
  • Verify that the float height is adjusted to the manufacturer's specification to prevent flooding.
  • Inspect the needle seat for debris to ensure a proper seal.
  • Use a soft-tipped screwdriver to avoid damaging brass jets during installation.

FAQ

This kit is designed specifically for the 2002 Polaris Sportsman 500 4x4 DUSE. It also cross-references with part number 26-1012.
This kit includes the essential internal components required to restore your carburetor, such as the float valve assembly, gaskets, O-rings, clips, jets, and adjustment screws with their corresponding springs.
You likely need a rebuild if you experience rough idling, poor throttle response, hesitation during acceleration, or fuel leaking from the carburetor bowl. These issues are frequently caused by degraded gaskets or clogged jets due to old fuel.
Before installation, it is best practice to remove the carburetor and thoroughly clean the body with a dedicated carburetor cleaner. Use compressed air to clear all internal passages. When installing the new components, ensure all O-rings are seated properly to prevent vacuum leaks, and do not overtighten the brass jets, as they can be easily damaged.
The primary cause of failure is the use of ethanol-blended fuels, which can break down rubber gaskets and O-rings over time. Additionally, leaving fuel in the carburetor during long periods of storage allows the fuel to evaporate, leaving behind varnish deposits that clog the small orifices in the jets.