my 05 sportsman 500 was burning way too much fuel and was sputtering after i first started it up, so i went to my polaris dealer to buy a carb kit and they said rebuild i can only buy separate phe. he also said the only things that wear are the needle jets and the floats can sometimes leak, but whats it sound like to you that would cause bad fuel milage and sputtering until its warmed up?

 

Here's a complete carb kit cheaper than the dealers needle and seat alone. Carb Rebuild Repair Kit Polaris Sportsman 500 03 05 | eBay Plus this carb has to be set right on the float assy or you can have rich running problems along with fuel leaks. Here's some BST40 carb rebuild pics(a little different application) on a KTM,but the same basic insides. Plus shows how to adjust the float. The BST-40 Bible - ADVrider. Another thing that was a problem on the 2005 models,but may not be part of your problem was the ecms that could cause problems,even if they have been replaced. I'd address the carb first.

 

i'd go for that but i don't really like ording online because i'm in canada and it takes a while to ship and shippings costly

 

do u think buying the needle and seat would help?

 

If I'm going to the trouble of tearing into a carb,I'm gonna replace something! Needle and seat is first on my list. You can just clean jets and reuse the float bowl gasket as long as you don't tear it. Float adjustment was one of the big problems on this carb. Just look towards the end of the picture link I posted and it shows how to set/check the float level.

 

Buying the needle and seat is a pretty cheap way to see if that's what's wrong, a good place to start. Here is a link for the carburetor diagram for that machine if you decide to go that route...OEM Parts

Also here is a decent video on how to clean your carb,

 

thanks i'll get the needle and seat and go from there