2004 Polaris Indy 500 Edge carb issues

[Saskatchewan2021]

First time posting so please bear with me. I bought a 2004 Polaris Indy 500 (also referred to as Edge), the guy I bought it from stated one of the carb needles were bent, so he replaced it. He started up the sled and had it idling, everything was good. Get sled home, and started driving it the next day. It took like 35 pulls on the first day I owned it to get it running. Thought it was something to do with the two hour drive trailering it. It lost power, quit running after 20min. After a while, got it back running, and limped it back to the shed. Figured it needed a carb clean, so stripped the carbs down, cleaned them, and then got it back up and running. Left the fuel shut off turned to "on" over the next four days. Engine flooded with fuel, drained engine with the two 10mm bolts at the base of the block.

The guy who sold me the sled, through in the remaining carb rebuild kit. All Balls Kit 26-1791. In researching the kit, I realize the kit is for 2004-2007 Polaris 500 XC/SP. Wrong kit, and it looks as though he used the replacement needle from that kit. The needle I require is part# 3131287 Needle, Jet | [9DFY1-54]. This needle can not be found anywhere. Is there a different needle/Jet combination that I can switch out so both carbs match?

The needle that came with the All Balls Kit is part# 3131253 Needle, Jet | [J8-9DFH6-57][500]. Is this one compatible with the needle that used to be in the sled? Should I switch out the main Jet to match this needle? The main Jet for a 2004 Polaris 500 XC/SP is part# 3130599 Jet, Main | [410].

The main Jet for a 2004 Polaris Indy 500 Edge is part# 3130139 Jet, Main | [#360].

The carbs do not look identical though so this might not work. So confused.

Also in my research I learned that the o-ring that seals the float valve does get hard, and fuel can flow past it. I'm not sure if this would cause the engine flooding issue. This sled has not run well at all since I bought it.

I can turn the fuel shutoff "on", run the sled and once started will run well, then it seems as though it gradually runs really rough, and before it quits, I give it full throttle and it will only go to 3500rpm, bog out and then I turn the fuel shutoff to "off". Keep the throttle fully pulled, and then the engine will start, and as the carb bowls empty of fuel as it gets burned, it runs better and better until the carb empties.

Any help would be greatly appreciated. Thanks in advance.

 

[850Switchback]

I would suggest starting over with a new kit that is right for the sled so you know all the components are correct since this one sounds like it is causing many issues at once. If All Balls doesn't have one, Parts Unlimited also sells machine specific rebuild kits for them. You can look it up through their website or Dennis Kirk carries them as well with a sled specific search.

 

[850Switchback]

Did a little searching, the 9 series needles are an OEM only part. The problem is finding a cross over number to match.

 

[Saskatchewan2021]

Now I see why it's impossible to find a 9 series needle. I measured the one that came in the All Balls Kit.
Total Length: 90.6mm
D-1 (10mm): 2.97
D-2 (20mm): 2.96
D-3 (30mm): 2.52
D-4 (40mm): 2.52
D-5 (50mm): 2.50
D-6 (60mm): 2.30
D-7 (70mm): 1.95
D-8 (80mm): 1.63
D-9 (90mm): 1.35

Next, I'll take out the one good remaining needle and measure it. I'll also try and find one through Parts Unlimited, and Dennis Kirk. I'll let you know how it goes. I'll also post if I find a decent replacement for it if I can't find the exact match.

 

[850Switchback]

I would also check the rest of the carb jets, nothing is going to be right. That kit he bought is for a Polaris Domestic Twin 500, you have the older Fuji "488" motor.

 

[bushwacker1]

The needles have different lengths as well as different tapers. The widest area can have different diameters where the taper starts so finding a similar needle would require measuring in several places to be sure it is a close match. If the correct needles are no longer available you may need to purchase a used set of carbs to get the correct ones. As 850 switchback stated it sounds like you have a fuji twin so the domestic twins will most likely be tuned differently. You may be able to use other needles from a liberty twin 500 or 600 but would need to go thru the process of tuning the air pilot jets and the mains to get to a safe tune. Polaris used 3 different part # for flat slides on the fuji twins 3131270, 3131349, and 3131560. The part # should be printed on one of the carbs. These all came with 9dfi1-54 needles, 2.0 cut away, 145 starter jets, and 40 pilots. Air jets were 1.0, 1.0, and .9 for the three carbs used. The last two have p2/825 needle jets, not sure on the 3131270 but most likely the same. Any 600 engine carbs will have different cut away on the slides, needles, pilots, and jet needles. The carbs you would be looking for were used on fuji twins 2001, 2002, 2003, 2004, 2005, and 2006.

 

[Mike-DRH]

You need the right jet needle period, unless you want to R&D the thing for the next ten years. Way to many combinations to chose from.

Go to your local hardware store for the orings, nothing special.

 

[George Majewski]

What is the best carb kit to buy?