Question about Polaris ATV

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I change the engine in my 1994 polaris 400L, im having a problem with the carbuator, its pusing the fuel out on the top air vent, where the small hose goes on it, and on the bottum of the carb where the other small hose goes on, also fuel comes out while it is running, what is the problem?

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The float or the float needle is the problem. Possibly during the changeover the carb was inverted or the seal on the needle could even have dried up inside if it was out of use for long. A speck of dirt or rust could be preventing the needle from closing.

Turn off the fuel, remove the fuel line to the carb, spray carb cleaner into the carb & drain it, spray again & drain again then hook it back up & try it running. Shut down immediately if it leaks & see below. If that fixes it, you're good.

Remember, FUEL is EXPLOSIVE. Allow things to air out once any fuel has been in the area as the fumes can lead to a tank some distance away!

There is a float needle you'll need to check to make sure it's sealing properly, or get a replacement. The dissasembly is pretty straight forward by viewing the part so I'll leave that to you. If you aren't familiar with the internal parts, you may want to get a manual for the schematic diagrams (check with the dealer the diagram probably comes with a carb rebuilld kit that includes gaskets & the float needle & seat) when you open this carburetor up you will find the float, it moves up & down with the fuel level & by doing so pushes the attached needle into the hole blocking the fuel intake(that is your main fuel line to the carb connection. The way the needle attaches or rides on the float is important & should be carefully noted prior to dissasembly. (Digital camera are helpful to review at no cost!) Really it's that simple.

The issue is, if the float sticks, or the needle leaks, you get fuel continuing to filll the carburetor as you've seen & it will come out of all of the openings eventually if the seal doesn't work or If it isn't set properly. Some of the floats are brass cans & they get holes in the solder or a bad seal, or there can be something small like a string, or speck of rust, in the fuel line sticking at the spot where the needle can't completely seal. Good luck

Posted on Feb 03, 2010

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  • Master
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You have some bad seals and sounds like a sticking float or needle valve
Get the rebuild kit for the carb, give it a good cleaning, and replace the seals...that should fix ya right up

Most likely when your engine went bad some debris got thrown back into the intake and sucked into the carb.

Posted on Feb 03, 2010

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99 Polaris Sportsman 335, idles fine but when you give it gas it sounds like it bogging out. We have replaced plug and needle and seat. Runs even worse with the air cleaner on. Help


It sounds like the camshaft is going flat. The exhaust lobe on the camshaft is the first to wear. Basically the exhaust isn't opening the entire duration it needs to expel the exhaust. This will cause the bogging issue. Polaris uses an overhead camshaft, which fortunately, makes it easier to replace. To check the camshaft:
1. Remove spark plug
2. Remove the large bolt on top of the recoil starter
3. Rotate the engine with the pull rope until the "T" mark on the flywheel is visible through the hole the bolt was removed from
4. Remove 8 screws on valve cover, fuel tank removal is not necessary but gives you more room
5. Remove 4 bolts from rocker arms, lift rocker arms off camshaft
6. Rotate engine again with pull rope to inspect camshaft. The center of the camshaft is the exhaust lobe, intake lobes are on the outsides of cam. The exhaust lobe should be about the same height as the intake lobes, and will be noticeably flat
To replace the camshaft:
1. Remove camshaft gear access cover on right side of engine
2. Rotate engine again until the "T" mark on flywheel is visible, 2 dots on the camshaft gear should be at the top of the gear and will be parallel to the mating surface of the valve cover
3. Locate the chain tensioner, 2 small bolts holding tensioner to cylinder and 1 large bolt in the center. Remove the large center bolt to remove tension. There will be a spring and pin inside tensioner so be careful not to let it fly out.
4. Remove screws holding gear to camshaft, leave the gear on the chain
5. On the left side of the engine, clamp the coolant hose going into the thermostat cover
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7. There will be a round cover on left side of engine with 3 screws, remove that cover and pull the camshaft out through that hole.
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15. Option B is to take it to a Polaris dealer to avoid the hassle of trying to do it yourself!
Hope this helps, if you need any more assistance let me know, Daniel

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