4.4
CARBURATION AND FUEL SYSTEM
© Copyright 2011 Polaris Sales Inc.
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
GENERAL INFORMATION AND
SPECIFICATIONS
Carburetor Jetting
IMPORTANT: The following guidelines must be followed
when establishing a main jet setting:
1. Select the lowest anticipated temperature and
altitude at which the machine will be operated.
2. Select the correct main jet according to the engines
fuel/performance requirements.
Mikuni Jet Part Numbers
Main Jets Pilot Jets
Jet Number Part Number Jet Number Part Number
130 3131537 25 3131538
132.5 3131536 27.5 3131539
135 3131535 30 3131540
137.5 3131534 32.5 3131541
140 3131522 35 3131542
142.5 3131523 37.5 3131543
145 3131524 40 3131544
147.5 3131525 42.5 3131545
152.5 3131526 47.5 3131546
155 3131527 50 3131547
157.5 3131528 52.5 3131548
160 3131529 55 3131549
162.5 3131530 57.5 3131550
165 3131531 60 3131551
167.5 3131532 65 3131552
170 3131533 70 3131553
NOTE: It is strongly recommended that Polaris Carbon
Clean be added regularly as directed to the fuel systems
of all Polaris ATVs. Carbon Clean stabilizes the fuel,
preventing clogging of the small passages and orifices
common to ATV carburetors, and ensures constant
performance, reliability and easier starting.
Special Tools
SPX Corporation - 1-800-328-6657 or
http://polaris.spx.com
A main jet that is too small will cause a lean
operating condition resulting in serious engine
damage. Select the correct main jet carefully for
elevation and temperature according to the charts in
the Specifications section or in the Owner’s Safety
and Maintenance Manual for each particular model.
PART NUMBER
TOOL
DESCRIPTION
2870975
Mity Vac
TM
Pressure Test
Tool
2872314
Carburetor Float
Adjustment Tool
PU-50326 Fuel Pump Service Tool
Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors
or in a well ventilated area.
Do not overfill the tank. The tank is at full
capacity when the fuel reaches the bottom of
the filler neck. Leave room for expansion of
fuel.
Never start the engine or let it run in an
enclosed area. Gasoline powered engine
exhaust fumes are poisonous and can cause
loss of consciousness and death in a short
time.
Never drain the float bowl when the engine is
hot. Severe burns may result.
Do not smoke or allow open flames or sparks
in or near the area where refueling is
performed or where gasoline is stored.
If you get gasoline in your eyes or if you
should swallow gasoline, seek medical
attention immediately.
If you spill gasoline on your skin or clothing,
immediately wash with soap and water and
change clothing.
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