FUEL SYSTEM/CARBURETION

Carburetor Disassembly - Mikuni CV

1. Remove carburetor diaphragm chamber cover.

2. Remove return spring and vacuum slide.

3. Invert vacuum slide and remove spring seat and jet

needle from slide. Note position of "E" clip and
washer.

4. Remove pilot air jet.

7/96 4.30 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Carburetor Disassembly· Mikuni CV

5. Remove carburetor float bowl.

6. Remove idle stop screw, washer and spring.

7. Using a small pin punch or a spring loaded automatic

center punch, remove float pin, float, and inlet needle.

8. Remove inlet needle seat retaining screw along with

plate, and carefully remove needle seat. NOTE: Do
not use a pliers to remove the seat or damage may
occur.

Polaris Industries Inc. 4.31 7/96

FUEL SYSTEM/CARBURETION
Carburetor Disassembly - Mikuni CV
9. Remove main jet and washer.

10. Remove needle jet by carefully pushing it out through

the top of the carburetor from the float chamber side.
Do not push on the inside of the needle jet or damage
may occur to the main jet threads.

11. Remove pilot jet.

12. Remove the pilot mixture screw with spring, flat

washer, and O-Ring.

NOTE: The starter jet is not removeable.

7/96 4.32 Polaris Industries Inc.

 FUEL SVSTEM/CARBURETION
Carburetor Cleaning - Mikuni CV
1. Thoroughly clean the carburetor body, jets, and all passages with carburetor cleaner or electrical contact
cleaner.

A WARNING

Protect eyes from contact with cleaner. If you get cleaner in your eyes or if you swallow cleaner, see your doctor
immediately. Some carburetor cleaners are extremely caustic and extended periods of soaking can loosen the
adhesive sealer on the passage drill-way plugs. Do not soak rubber or plastic components (such as the vacuum
slide diaphragm, needle seat screen, or O-Rings in caustic cleaning solutions. Irreparable damage may occur.
Do not use agitator type carburetor cleaning equipment. Rubber parts must be cleaned with mild detergent and
hot water only.
2. If the carburetor is extremely dirty or contaminated with fuel residue and varnish, soak for short periods only in
carburetor cleaner, and rinse in hot water.
3. Replace the jets if they are extremely dirty or have a buildup of fuel residue or bacterial growth. Even a small
amount of residue will reduce the flow characteristics of the jet.
4. Verify all passages and jets are unobstructed by spraying electrical contact cleaner through the passages.
CAUTION: Do not use wire or welding tip cleaners on the jets as the orifice size may be altered.
5. Use low pressure air to dry carburetor body and all components.

Carburetor Inspection
1. Inspect the diaphragm for holes, deterioration, or
damage. Make sure the diaphragm is pliable but not
swollen. The diaphragm should fit properly in the
carburetor body. Replace diaphragm assembly if
diaphragm is damaged.
2. Inspect the diaphragm return spring for damage or
distortion of the coils.
3. Inspect the slide for wear, scratches, or damage. It
should move freely in the jet block. Replace if
necessary.

4. Inspect jet needle for wear, bending, or other damage.

5. Inspect needle jet. Air bleed holes must be clear.
Check for wear at the top inside surface where the jet
needle enters the needle jet.
6. Inspect the inlet needle seat for wear, damage and
foreign material. Check the inside for abrasion or wear
from the needle.

7. Inspect O-ring for cuts, nicks and abrasions. The

O-ring must fit snugly on the needle seat and in the
carburetor body to ensure a leak-free sea\. The screen
must be clean and fit snugly on the needle seat.
Replace needle and seat assembly if necessary.

Polaris Industries Inc. 4.33 7/96

FUEL SYSTEM/CARBURETION
Carburetor Cleaning - Mikuni CV

8. Inspect the inlet needle tapered surface for any sign of

wear or damage. Be sure the spring loaded pin is free
moving and returns freely when pushed. The inlet Good Condition Worn, Deposits
needle and seat should be pressure tested after
assembly. See Carburetor Assembly/Adjustment, #

pages 4.36 - 4.38.

9. Inspect the pilot mixture screw for damage. Make sure

the small tip is not bent or missing. The washer must
be in place between the O-Ring and spring on
reassembly. Check the O-Ring for cracks, damage or
wear. Replace if necessary.
10. Inspect the float, float pin, and pin mounting boss for
wear or damage. The float should pivot freely on the
pin without binding. Replace the float assembly, pin, or
carburetor body if worn.
11. Inspect the starter plunger for wear, cracks, foreign
material or bending. Check the seating surface in the
carburetor for damage, burrs, or foreign material.
Inspect return spring, making sure it is not damaged or
weak.

7/96 4.34 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Carburetor Cleaning - Mikuni CV

12. Check the overflow stand pipe in float bowl for cracks
or bending. Be sure the pipe is clear. Fill the bowl with
liquid and check for leakage out the drain orifice. If the
bowl drain leaks, inspect tapered surface of the screw
and seating surface. Check the bowl sealing O-Ring
for damage or wear.

13. Check the starter jet to be sure it is clear.

14. Check the vent passages and impulse source for

cracks or obstructions.
15. Inspect the throttle shaft. It should return freely and
completely when opened and released. Check the
shaft for excess play or movement.
16. Inspect the throttle plate and retaining screws. Make
sure the plate is closed all the way and is centered in
the bore. Check to be sure the screws are tight.

Polaris Industries Inc. 4.35 7/96

FUEL SYSTEM/CARBURETION
Carburetor Assembly - Mikuni CV

1. Install the needle jet making sure the slot is aligned with
the tab in the jet block.

2. Install the main jet and washer.

3. Install the pilot mixture screw, spring, washer, and

a-ring as an assembly. Lubricate the a-Ring with oil or
light grease before installation. CAUTION: Do not
damage the a-ring during installation. Turn the screw
in until it lightly contacts the seat. Back out the
specified number of turns 1.

4. Install the pilot jet and pilot air jet.

5. Install the inlet needle seat with screen and a-ring.
Lubricate the a-ring with oil or a light film of grease.

6. Install the plate and retaining screw.

7. Install the float with inlet needle and install the pin.
CAUTION: Do not bend the float during installation.

1 NaTE: The final pilot (idle) mixture must be adjusted witr

the engine running. Refer to Page 2.12a.

5/98 4.36 Polaris Industries Inc.

 FUEL SYSTEM/CARBURETION
Carburetor Assembly/Adjustment - Mikuni CV
Float Height Adjustment
1. Place the carburetor on a level surface in the position
shown. In this position, the float tongue will lightly
contact the inlet needle valve pin without compressing
the pin spring.
2. Measure the height from the float bowl mating surface
to the top of step in float (highest point) as shown. Both
sides of float should be parallel to each other. The
measurement should be made at the mid-point on the
top of the float using a vernier caliper. When
measuring the height be sure the inlet needle valve
spring is not compressed .

...

FIQafHeight:
.,
Std:BST34. ···13~Orrifl,l(~5t~O:i:~ ,.• rtlJil
B,ST40·· 14~7nun(.~an±.tmm.···

3. If adjustment is necessary, bend the tongue slightly.

Bend tongue to adjust.

4. Install the float bowl. Invert the carburetor and install a

Mity-Vac™ (PN 2870975) to the fuel inlet fitting. Apply
5 PSI pressure to inlet fitting. The needle and seat
should hold pressure indefinitely. If not, inspect needle
and seat and seat O-ring.

2
5. Install the "E" clip on the jet needle in the proper 3
position. Inspect the needle closely for wear and 4
replace both needle and needle jet if needle is worn. 5

Needle Grooves

Polaris Industries Inc. 4.37 5/98

FUEL SYSTEM/CARBURETION
Carburetor Assembly - Mikuni CV

Float Height Adjustment, Cont.

6. Install the plastic spacer washer on the bottom

Forward
of the needle and slide it up to the "E" clip.

Spring

/ '"

7. Install the jet needle assembly into the vacuum Pilot Screw /
slide and install the slide into the carburetor body.
Be sure the tab on the outer edge of the
diaphragm is positioned properly in the Idle Speed Screw
carburetor body.
8. Fit the diaphragm sealing lip into the groove in the
carburetor body.
9. Install the spring seat washer and install the spring.
10. Install the diaphragm chamber cover and tighten the screws.
11. Check for free movement of the slide and make sure it returns smoothly and completely.

12. Install the idle stop screw with spring until it lightly contacts the throttle shaft stop arm. Turn the screw in 1 1/2
turns from this point to provide a base setting. Final idle speed must be adjusted with the engine running and
warmed to operating temperature. Move the throttle actuator arm to full open and make sure operation is
smooth and arm returns quickly and completely to closed position (against the idle speed screw).

5/98 4.38 Polaris Industries Inc.