Assembly; Carburetor Syncronization; Throttle Valve Synchronization - Polaris 2007 Two Stroke Service Manual

FUEL DELIVERY

Assembly

1. Install the main jet (20), pilot jet (21), and starter jet (22).
2. Install float/needle & seat assembly (19).
3. Place carburetor in an inverted position.
4. Connect a pressure tester (PN 2870975) to fuel inlet fitting.
Apply 5 psi pressure and observe for one minute. The
needle and seat should hold pressure indefinitely. If the
pressure drops, carefully inspect the needle and the needle
seat. The needle can be replaced (needle comes with float
and seat).
5. Carefully inspect float bowl gasket and replace if
necessary.
6. Install float bowl (16) on carburetor with water trap/drain
plug (15) and single screw (16) on the bottom of the
carburetor.
7. If throttle slide was removed, install throttle slide (11) so
that the wider face is facing the engine side of the
carburetor.
8. Install the funnel gasket (13) and funnel (12) onto the
carburetor. You will have to lift the throttle slide up and
place the smaller face into the funnel area.
9. Install funnel screws (10).
10. Install the e-clip (8) in the desired position on the jet needle
(7).
11. Slide the plastic washer (9) on the jet needle so that it is
positioned to rest on top of the throttle valve when
assembled.
12. Install carburetors on engine.
13. Synchronize the carburetors. See "Throttle Valve
Synchronization" in this chapter.
14. Replace top cap gaskets (3), cover (2) and screws (1).
15. Check throttle lever free play. See "THROTTLE LEVER
FREE PLAY" on page 3.24.
4.14

CARBURETOR SYNCRONIZATION

Throttle Valve Synchronization

Mikuni TM style carburetors are synchronized at wide open
throttle without the engine running. The MAG side carburetor
is the adjusting carburetor, the PTO side carburetor has a non
adjustable set screw on the throttle shaft. The PTO carburetor is
considered the base carburetor. All adjustments are made to the
MAG carburetor
1. Remove the air box.
2. Remove the carburetor tops.
3. Hold the throttle wide open with the bell crank on the
carburetor.
4. The bottom of the throttle valve should be flush with the
top of the carburetor intake area.
5. If they are not flush, hold the PTO carburetor flush with the
top of the intake area of the carburetor.
6. Turn the throttle slide synchronization screw until both of
the throttle slides are flush with the top of the intake area
of the carburetor.
7. Once the PTO carburetor slide is flush, loosen the Phillips
head screw, located under the top cover on the MAG
carburetor.
Throttle slide sync screw