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Polaris Sportsman ATV Carb Ultrasonic Cleaning

Being the world’s first ATV equipped with Independent Rear Suspension or IRS, the Polaris Sportsman was made for bike enthusiasts who prefer an aggressive ride. This ATV has a lot of power, good traction and a rough-and-ready suspension system as well. Because the Sportsman is a serious trail machine, owners make sure that their ATVs are clean most especially on the inside, where dirt and gunk can accumulate.

A clean, well-tuned carburetor is a key factor in the performance of your Polaris Sportsman ATV and nothing makes cleaning carburetors faster, safer and easier than an ultrasonic cleaner. Whether you operate a Polaris Sportsman ATV service shop or do it yourself, you’ll be amazed at just how thorough an ultrasonic cleaner can be in removing varnish, grease, oil and other contaminants from one of the most intricate assemblies on your Polaris Sportsman ATV.

Here you will learn:

  • How an Ultrasonic Carburetor Cleaner Works
  • How to Select and Set Up your Ultrasonic Cleaner
  • How to Remove, Clean and Reinstall your Polaris Sportsman ATV carburetor

How Ultrasonic Parts Cleaners Work on your Polaris Sportsman ATV Carburetor

Digital ultrasonic cleaners are used in a wide range of applications to remove virtually any soil or contamination by using the power of cavitation action. This is the term used to describe the implosion of billions of minute bubbles contacting carb parts being cleaned. The bubbles are created by generator-powered ultrasonic transducers bonded to an ultrasonic cleaning tank and typically operate at an ultrasonic frequency of 37 to 42 kHz (37,000 to 42,000 cycles per second).

When the bubbles implode contaminants are quickly and safely blasted away from wetted surfaces without damaging delicate carb parts. So tiny are the bubbles that they penetrate minute cracks, crevices and blind holes impossible to reach by hand scrubbing using conventional parts washers or aerosol sprays The ultrasonic parts washer will complete the job in less than an hour, meanwhile freeing you up to attend to other tasks. And it will do it in an environmentally friendly manner because the sonic cleaning formula is a biodegradable concentrate that minimizes disposal problems.

How to Select and Set Up your Polaris Sportsman ATV Ultrasonic Carb Cleaner

Ultrasonic carb cleaners come in a variety of sizes from bench top units to a floor-mounted industrial ultrasonic cleaning machine, so you can select any size you need. Our most popular 1½ gallon models for cleaning one carburetor at a time are the TOV150-6L and EH150EL. Select an ultrasonic carb cleaner equipped with a heater to improve the ultrasonic carburetor cleaning process.

Whatever the model and size ultrasonic carb cleaner you use there are steps to take before cleaning begins.

  1. Fill the ultrasonic carb cleaner tank to the fill line (or approximately 2/3 full) with ultrasonic cleaner solution diluted per manufacturer’s recommendations.
  2. Turn on the ultrasonic cleaner, set the heater to approximately 70°C, and operate the ultrasound for about 30 minutes to drive off cavitation inhibiting entrained air. Degassing is complete when bubbles stop coming to the surface and must be performed every time the tank is filled with fresh cleaning solution.

How to Remove, Clean and Reinstall your Polaris Sportsman ATV Carburetor

Step 1: Removing the Carburetor

First, turn off the fuel. Remove both the seat and side panels. The breather box and associated hoses must also be removed as well. Loosen the fuel tank and move the two 2-inch tubes to have access to the carburetor. The bracket holding the rear end of your Polaris Sportsman carb to the assembly must also be removed. Next, remove the fuel lines and loosen the front clamp holding the carburetor to the engine intake.

Disconnect the accelerator cable. In order to remove the throttle, you will need to use a screwdriver to remove the cover plate held by four screws. Once this is done, remove the cable connected to the throttle plate. It is important to know that the choke comes out as you loosen the threads in one piece. After the threads are loosened, the throttle can now be removed. You can now pull your carb from the assembly.

You now hold in your hand, your Polaris Sportsman ATV carburetor.

Congratulations! You have successfully removed your Polaris Sportsman carb from your ATV! You may now proceed with the next step.

Step 2: Cleaning the Carburetor

Although you can clean your carburetor without any disassembly you will achieve the most thorough cleaning with partial disassembly to allow the solution into the float chamber. Remember that only surfaces that are wetted by the cleaning solution will be cleaned. Fine mesh baskets can be used to hold very small parts.

Set the thermostat to 70°C in your ultrasonic cleaner from While the solution is heating, place your carburetor parts in the basket taking care that they do not touch each other. Once the operating temperature is reached lower the basket into the cleaning solution and set the timer for 40 minutes. Cleaning time depends on the condition of the carburetor and may have to be adjusted.

At the end of the cycle remove the components from the bath. If they are not clean replace them in the bath until the cleaning is complete. Then rinse them in fresh water to remove all traces of the cleaning solution and allow them to dry.

Safety note: DO NOT reach into an operating ultrasonic bath. Instead remove the basket if you want to inspect or rearrange the parts.

Step 3: Reinstalling the Carburetor

To make things easier, connect the choke and throttle cable to your Polaris Sportsman ATV carb first. Return the choke onto the carburetor by tightening the threads. Insert the throttle back in, making sure it stays secure in its original position. Tighten the four screws to keep the cover plate in place. Once this is done, return the carb to its original position. Tighten the front clamp to hold your Polaris Sportsman ATV carb for the meantime. You may now connect your accelerator cable.

Return the bracket holding the rear end of your carburetor to the assembly and tighten it so your Polaris Sportsman carb stays firmly in place on your ATV. Move the two 2-inch tubes again to hide the carburetor from view. It’s now time to return the fuel tank to its original position. Remember to return the breather box and associated hoses of your ATV to their original places. Now for the last step, put the side panels back and install the seat.

Admire the piece of work you just put back together.

Voila! Start the engine, and your Polaris Sportsman ATV should be good to go.

More Operating Tips

Oils that rise to the surface of the sonicator water bath should be skimmed off and disposed of properly. When the solution becomes discolored or cleaning time takes longer it is time to replace it. Drain the tank and dispose of the spent solution according to local regulations. Take the time to remove sludge that settled to the bottom of the tank. Clean the tank using a cleaning process recommended by the manufacturer.

Questions: Contact the iUltrasonic ultrasonic cleaning experts at 973 821-4400

Disclaimer: This advice is not provided by a licensed mechanic. Follow at your own risk. We assume no liability for any damages caused by following the advice in this article.


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