First off to those reading this that are willing to help me, thank you. I know this is long so I apologize but I like to include as much info as possible. I bought an 02 Sportsman 700 a few months back and have had no time to work on it. I know that one fix for poor running machines is a new ignition system but I want to find out if I can get this thing running good without the $500 upgrade so I'm in the process of rebuilding the carb and have a few questions. I live in VA and will probably mostly ride in this area, up in WV and possibly up in MI (0 - 3000 ft)
The service manual says for the MAIN JET:
0-6000 ft & above 40*F 162.5
0-6000 ft & below 40*F 167.5
and that a 162.5 was installed stock from the factory in the Mikuni BST 34 Carb
However on the Polaris website if you go to order parts they note that the jet they're selling is a 152.5 or 155.
I bought an aftermarket carb rebuild kit and it included a 157.5 jet and there was a 162.5 in the carb when I tore it apart
1) What jet should I put back in? The 157.5 or the 162.5?
The service manual says for the PILOT JET that a 45 was installed stock from the factory in the Mikuni BST 34 Carb which also aligns with what they're selling on the Polaris website and that's what was in the carb when I tore it apart. In the aftermarket carb rebuild kit, it included a 47.5.
2) Is there any reason to even consider the 47.5 or just use the 45 and be on my merry way?
Finally, the last question: In the service manual it notes in the "Float Height Adjustment" section that the float height should be set between 13 and 14 mm, however earlier in the service manual it notes that it was set at the factory at 14.7 mm +/- 1 mm so.....
3) What height should I set the float at?
I feel like on my 99 Sportsman 500 I had that the "proper" adjustment was for the flat part on the float to be parallel with the float bowl surface but that was a few years back.
The service manual says for the MAIN JET:
0-6000 ft & above 40*F 162.5
0-6000 ft & below 40*F 167.5
and that a 162.5 was installed stock from the factory in the Mikuni BST 34 Carb
However on the Polaris website if you go to order parts they note that the jet they're selling is a 152.5 or 155.
I bought an aftermarket carb rebuild kit and it included a 157.5 jet and there was a 162.5 in the carb when I tore it apart
1) What jet should I put back in? The 157.5 or the 162.5?
The service manual says for the PILOT JET that a 45 was installed stock from the factory in the Mikuni BST 34 Carb which also aligns with what they're selling on the Polaris website and that's what was in the carb when I tore it apart. In the aftermarket carb rebuild kit, it included a 47.5.
2) Is there any reason to even consider the 47.5 or just use the 45 and be on my merry way?
Finally, the last question: In the service manual it notes in the "Float Height Adjustment" section that the float height should be set between 13 and 14 mm, however earlier in the service manual it notes that it was set at the factory at 14.7 mm +/- 1 mm so.....
3) What height should I set the float at?
I feel like on my 99 Sportsman 500 I had that the "proper" adjustment was for the flat part on the float to be parallel with the float bowl surface but that was a few years back.
