Fuel tank removal - Polaris ATV Forum
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post #1 of 15 (permalink) Old 04-09-2012, 11:24 AM Thread Starter
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Fuel tank removal

I need to take my fuel tank off an 07 Sportsman 800 and am reading I need to open the relief valve and release the fuel pressure. Do I need have the Polaris fuel pressure tester thats over $100 or is there a cheap solution. Ive never done this and want it done right but will probably never need this tool again as Im selling the machine after I fix it.

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post #2 of 15 (permalink) Old 04-09-2012, 12:40 PM
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If you have a fuel pressure tester with a relief button, then use it. If not, wad up a paper towel around a small screwdriver and press in on the valve for a couple seconds. There won't be enough to get the whole paper towel wet.

BTW, make sure you have no open source for ignition nearby.

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2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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post #3 of 15 (permalink) Old 04-09-2012, 12:41 PM
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To release the pressure, use a screwdriver. The test pot/valve is a schrader valve, same as a tire valve. Just depress the little pin in the center to relieve the pressure in the line. Oh and don't look directly at it when you push in the valve. LOL!

"Big Bad Wolf" 2004 Sportsman 700 EFI, Mine
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post #4 of 15 (permalink) Old 04-09-2012, 02:28 PM Thread Starter
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thanks guys, got it done. Now its almost off and can't get that fitting off the fuel pump. Manual says to squeeze and pull but its not happening?? Any suggestions?
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post #5 of 15 (permalink) Old 04-09-2012, 04:17 PM
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I'm thinking you mean getting the hose disconnected from the top of the fuel sender assembly.

There is a white piece in the fitting that you have to squeeze each side of and then slide the white piece as far to the side as possible. That unlocks the fitting from the metal tube and then you can pull the hose off. After you get the hose off it will be perfectly clear how it works.

It goes in pretty far so make sure you put it all the way back on when reinstalling.

Stew

2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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post #6 of 15 (permalink) Old 04-09-2012, 05:40 PM Thread Starter
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Thanks for help guys!! got it done
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post #7 of 15 (permalink) Old 04-09-2012, 06:53 PM
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I had lifted the white plastic with thin screwdriver then it slid upward, releasing the metal pipe. Easy to slide back on after.

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post #8 of 15 (permalink) Old 04-10-2012, 05:00 AM
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Just curious while we are on the topic. Does a person have to drain the fuel tank prior to removal. I have never done this but am sure I will need to at some point.

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post #9 of 15 (permalink) Old 04-10-2012, 08:59 AM
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Quote:
Originally Posted by KICKER431 View Post
Just curious while we are on the topic. Does a person have to drain the fuel tank prior to removal. I have never done this but am sure I will need to at some point.
I drained mine just so it would weigh less to fish out of the frame. As long as you put the tank cap on and maybe put a rubber cap over the pump outlet you could pull it if it died when the tank was full.
To drain mine (it was an intermintent pump failure) I connected just the hose off my fuel pump pressure tester, without the gauge, to the test port and put it in a gas can. I then started the quad up and let it run and the in tank pump emptied the tank for me.

"Big Bad Wolf" 2004 Sportsman 700 EFI, Mine
"Lil' Red" 1999 Sportsman 335, The Wife's Ride
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post #10 of 15 (permalink) Old 04-10-2012, 09:04 AM
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Quote:
Originally Posted by KICKER431 View Post
Just curious while we are on the topic. Does a person have to drain the fuel tank prior to removal. I have never done this but am sure I will need to at some point.
It doesn't lift straight out so you have to maneuver it a bit. You don't have to drain it but it sure makes it easier to do without 35 pounds of extra weight. Besides, if you take it off you might as well go ahead and clean it on the inside. I was surprised at the amount of dirt in it the first time.

Stew

2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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