Well it happened on a week long vacation.

Suddenly I was driving a very economical ATV. Fuel level was full up all the time.
So I was guessing my fuel level and continually topping up to be sure.

Fuel sender not working.

Today I had some time so I decided to take a look at the fuelpump and sender unit.

Hardest part was actually removing all the plastic needed to gain access to the fuel tank and remove it.

Once the fuel tank was removed it was a piece of cake.
Removing the fuelpump/sender unit is a bit fiddly so take care not to bend or damage anything.

With a simply Ohm meter check the range of the sender.
5 ohm for empty
90 ohm for full.
Checked out OK, so the electrical problem was higher up the wiring harness.

I noticed there was a little much dielectric grease on the connector.
So sprayed it with some contact spray, then some compressed air to clean everything up.

Disconnected the +12V at the fuel pump itself and did the onboard diagnostic on the machine itself.

Starting switch just on contact you can slowly go through the full motion of the fuel sender and see if it reacts on the display.

Everything was ok. So mounted everything up again.

Polaris employees really do their job well, every connector receives a decent dose of dielectric grease. Sometimes a little too much.

You really can't them for that can you.

Good info Chrisrccolleman maybe that's why mind doesn't light the top two bars of the gauge when it's full...

nbsportsman wrote:

Good info Chrisrccolleman maybe that's why mind doesn't light the top two bars of the gauge when it's full...

That or the floater isn't moving freely untill it reaches the top.

Here are some photos to show his description. Photos are of a 2006 sportsman 500 EFI.

Yep that's it.

Is it just me or do those top 2 pics look like different tanks?

The CVT ducting is off on the second picture as well the second pic is taken from the opposite side.