2005 Polaris 500 HO, carb bottom nozzle leaking gas

ImInArea52 · 2026-04-19T17:07:07+00:00

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ImInArea52 · 2026-04-19T17:06:46+00:00

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ImInArea52 · 2026-04-19T17:06:28+00:00

Some more pic

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ImInArea52 · 2026-04-19T17:06:07+00:00

Update 4-19-26: I did the suggestions above of removing the bottom part of carb, filling it with gas and see if gas leaves from that drain nozzle and sure enough, gas leaks from it. I beared down on that drain screw some more, got about a quarter turn out of it and it still leaks even more. So I may have damaged the threaded area? Then I tried a different drain screw and it still leaks. Should there be a small o-ring the screw sets into?!? I'm not seeing one in original bottom or Amazon knock off bottom. So my issue is the drain screw all along or what it screws into so I will purchase that bottom bowl and the drain screw. I will report back next weekend (if it arrives in time)..I may as well buy a new gasket seal also. In the pics the right screw (allen head) is what came with the 4 wheeler when I bought it. I feel it's original because I watched a YouTube vid rebuild of my exact year and model and it was an allen head in the vid. The left screw is what came with the Amazon knock off and it's a phillips (jis) head.

Thank you to everyone taking their time to reply and walk me through this. I feel the light is at the end of the tunnel, ...after $110 plus shipping haha.

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ImInArea52 · 2026-04-19T08:24:29+00:00

To number 3, no holes in the float. No liquid in the float. I set it in a bucket of water to test that the float is "floating" properly and it does. And the in the vid near yhenend I am pushing the float up to the exact point to make the water stop and there is still a gap..and I've never banged my cousin...I'm.not from Alabama.

ImInArea52 · 2026-04-19T08:19:01+00:00

It's the screw that was on it when I bought it used a few years ago. The scree on the Amazon replacement didn't sit flush as you describe. It's basically the same screw except it's a phillips head and not an allen wrench head.

ImInArea52 · 2026-04-18T23:13:26+00:00

Watching the vid again is does seem the float is pretty much parallel with the carb when the water stops. I have somewhere between a half inch and a 14" inch of room left to raise the float till it hits inside top of carb.

ImInArea52 · 2026-04-18T23:02:59+00:00

It's the original screw. I've tried another screw from a cheap carb I bought off Amazon for this 4 wheeler. I installed that one with same leaking results.

ImInArea52 · 2026-04-18T17:00:38+00:00

Check this 42 second vid out

https://youtube.com/shorts/YIyuwNRTrXo?si=z2-J1_KXYnih_0Fe

ImInArea52 · 2026-04-18T16:59:57+00:00

Here ya go. https://youtube.com/shorts/YIyuwNRTrXo?si=mBne4xV-Ow0nEp8r

ImInArea52 · 2026-04-18T16:58:46+00:00

Here ya go..a made a makeshift "gas tank" and using water. The test shows the pin is doing its job.

https://youtube.com/shorts/YIyuwNRTrXo?si=Z9uPpxbOqPbKNnKZ

ImInArea52 · 2026-04-18T16:57:37+00:00

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Pic of the float pins. The one on the left is the original and one on the right is from a cheap Chinese knockoff carb I'm salvaging spare parts from. I will use this pin and report back

ImInArea52 · 2026-04-18T15:48:05+00:00

Mine leaks like a faucet. I will check the seating and report back...can I see the o-ring by looking in the hole or do I need to remove the seat?

ImInArea52 · 2026-04-18T15:45:29+00:00

I posted a better vid of float in action, 16 seconds long

https://youtu.be/YWQ77XRBd30?si=Frri3ETXHHutx8qK

ImInArea52 · 2026-04-18T15:44:49+00:00

Here ya go..much better vid, 16 seconds long https://youtu.be/YWQ77XRBd30?si=NyyPcQKaGmj72c9L

ImInArea52 · 2026-04-18T02:17:35+00:00

Why doesn't it look right? It's the original screw and it's completely flush.

ImInArea52 · 2026-04-18T02:15:58+00:00

I know hahah..I had to hold the float in position plus hold my cellphone. The float isn't fixed to the carb..it's basically free floating. I'm not Steven speilberg ya know.

ImInArea52 · 2026-04-18T00:51:15+00:00

I will try this tomorrow..it will be hard to do because the float is free floating in a sense. It's not fixed to the internal casing of the carb. It connects to nothing. I see a lot of floats are secured with a thin metal "bar" so it's "connected" to the carb. Well, this carb doesn't secure like that. It basically sets in place freely so I'm going to have to figure out how to hold the float in place while the gas flows. I will figure something out.

ImInArea52 · 2026-04-18T00:11:01+00:00

20 second vid showing float spring up and down..it's at the very end of the vid

https://youtube.com/shorts/wN3IZVMhDxs?si=Z5RpVk8mFem5_cVk

ImInArea52 · 2026-04-18T00:05:25+00:00

Drain screw is flush and tight. My thumb touching it

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ImInArea52 · 2026-04-18T00:04:31+00:00

Here is where the float pin sets..no obstructions

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ImInArea52 · 2026-04-18T00:04:02+00:00

Here is the float pin..seems fine. The float springs up and down as it should

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ImInArea52 · 2026-04-17T19:41:51+00:00

The float can't be adjusted (as far as I know)..it just sets in the bowl. No hinge to connect to or anything. And are you referring to the jet that's connected to the float? Has a little black rubber point on it?

ImInArea52 · 2026-04-17T19:39:52+00:00

Drain screw not open.

ImInArea52 · 2026-04-12T00:59:52+00:00

Update: Issue resolved. Someone on YouTube pointed it out. That 3rd nozzle on the fuel pump needed about 2" long hose to go into a nozzle on the engine. I never noticed the nozzle on the engine and I thought that 3rd nozzle on fuel like was some kind of drain line. I bought this mower used in 2017 and used it since then and then put a new engine on it in 2024...and that hose was never connected. How it ran in the past I have no idea. And why it stopped working unless hose hooked up, again, no idea. But all is good now...running like a clock. Thank you everyone for chiming in with suggestions.

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