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Old 12-26-2012, 11:40 PM   #1 (permalink)
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Polaris 800 2003 to 2001 Carb Swap Fittment

So i have a question about carbs. I have an 03 VES 800 with twin pipes and a 159 track, I am need ing a new set of carbs, will the carbs from a 2001 800 non-ves twin 159 track work? it looks the same and has the TPS, looks like jetting might be different though. Any thoughts?
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Old 12-27-2012, 12:06 AM   #2 (permalink)
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Should be the same. Jet to the VES engine specs, including jet needle and you should be fine. What's wrong with your carbs?
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Old 12-27-2012, 06:14 PM   #3 (permalink)
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the pilot jet got rounded off inside the carb, and i tried to drill it out and jacked it up. So now i gotta get these to work. So i installed them today, and the round intake side of the carbs is longer where it goes into the airbox, not sure if i can get it into my airbox, and also there is no air screw, just what looks to be an air jet??? So i am trying to remove the face or intake side of the carb to swap them out so I get the longer tubes and also the air screw back, how does it come off? It looks like I gotta take the top off and somehow remove the slide that goes up and down with the needle on it? Not sure how it comes out. Any help would be greatly appreicated, Bruce
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Old 12-27-2012, 08:57 PM   #4 (permalink)
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Some of the Mikuni TM40's dont' have air screws and use the air jet in the front of the carb instead. They seem to work fine, if you need to fine tune, you just use the fuel screw.

Try putting the carbs in the airbox side first then into the carb adapters. You may be able to slide the carbs into the airbox to make stuff fit. I had to do that on a few cats I have owned... it's worth a shot...
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Old 12-28-2012, 06:14 PM   #5 (permalink)
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So i tried to put the carbs in the airbox first and when i tighten the band clamp on the intake boot because they are sitting out of the boot a bit it pushes it out more when i try to tighten the band clamp. How do I remove the intake side of the carbs? looks like the whole plate will come off after I remove the screws, bit something is holding it from the top. Any suggestions.
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Old 12-28-2012, 08:09 PM   #6 (permalink)
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To change the air funnels, you will have to remove the two screws from the top of the carb. Inside, you will see a screw surrounded by a nut. Remove that, it will allow you to lift the plastic slide out of the way of the air funnel. I would do one, then the other so you don't lose any adjustment. Don't know if that matters...
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