Instructions for Rebuilding Carburetors
on a Polaris Watercraft
You may download a PDF copy of these instructions by
right clicking this link polarcarbs.pdf and
choose “Save Target as” on you PC.
(1) These are the tools needed for the carb rebuild.
You will also need a Service Manual and pop-off pressure gauge tester.
(2) Tap the (in) fitting 5MM X .8.
The fuel in-line will be plugged with a 5 X .8 allen head bolt using lock-tite on the threads.
(3) Remove fuel rail plate and or clean fuel filters.
Inspect orings and re-place if needed.
(4) Re-install the fuel rail plate, loosely and use the flame arrestor base to align the carbs. Tighten the fuel rail screws.
(5) Install the new fuel lines and make 20” tails to be cut to fit later.
The fuel line (in) is now fed between the carbs instead of the PTO carb #3 for even delivery.
(6) After the carb bodies are clean, test the pop-off pressure as shown. Pump pressure, close the return and other input. The nee-dle will pop open, read the pressure gauge. You can use water on the needle to help you see it pop, if there is a leak. The differ-ence should be no more than 1 pound.eo.
(7) Remove the check valve and lap the plate on 400 wet dry paper. Re-install check valve..
(8) Dry carbs when you are done with pressurizing the airflow. Spray the inside with W-D 40, Carbs should look like this be-fore reassembling.
(9) Replace original fuel pump with a dual output pump.
When cleaning the carbs, do not dip them, use spray cleaner, only. Dipping them will damage the shaft seals.
