Just purchased a used 2001 sportsman 500 with 200 miles on it and it leaks gas from the overflow off the carb. I changed the needle and seed, took the carb to the dealer and had the dealer reset everything to specks and still leaks.
Pressure testing is easy. All you need is a squeeze bulb with a guage. Put the float and needle in and inser the floa pin. Invert the carb so that gravity pushes the float to the "up" position. Pump air into the fuel inlet and watch the guage on the pump. you should get at least 8-10 psi of hold. It may go up to 15 psi before it loses seal and bleeds off some. If it pumps up to about 10, then you see the guage falling, spray some wd40 around the needle and seat and pump it back up to about 10 psi. If you see the wd40 bubbling out around the needle, then the needle/seat are bad. If you see the bubbles coming from OUTSIDE the seat, the O-ring behind the seat itself is leaking and not the needle and seat.
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