2006 Sportsman EFI Fuel Guage

[4play]

ook into the fuel tank and rock the machine back and forth.... see no fuel? better start heading back lol

[Cableguy657]

would this also cause the gauge to read wrong?
like a quarter of a tank and it still shows full and when its almost empty it only comes down two bars from full?

[4play]

yup, maybe the float is stuck or the sending unit is bad..

[kent@kroekers.com]

Originally Posted by gfyoung3

Hi - I'm new to the forum. I recently bought a 2006 Sportsman 500EFI. I can not figure out how to get the fuel guage to work. The owner's manual indicates it should be on the electronic display. Nothing shows up there. I can not find a reserve swictch like my old polaris has. Am I missing something here? Shouldn't there be a fuel gauge or reserve switch?

Thanks

I have the same problem with my 2008 500 efi. Had the sensor out and it turns out the small plastic piece that acts as the electronic sensor is broken. It is a simple circuit board. 100 hours and the second major electrical issue. Not impressed. Also had to replace the complete wiring harness. Not going to replace the sensor if it only last 100 hours. Does any one know if there is a mechanical cap-gauge that would fit this tank?

[got steel]

Originally Posted by 4play

trust me, thats the first place i would check when mine did that I took the guage pod apart made sure the conections were tight, they were so i moved to the tank.... it's not hard, just time connsumeing.... this is what u do...

1. remove front rack. 4 13mm or 14mm bolts inside you can clearly see, there, 2 torqs per side by the latch and 2 under holding the fender flare's to the rack.... remove the whole front rack.

2. remove the plastic clips holding the plastic to the foot rests. remove that cover under the handle bar headlamp by pullling up on it. remove the seat. you will see 2 bolts one per side holding the plastic to 2 metal brackets remove the screws remove the gas cap. Now you can remove the plastic it helps if you get a buddy to help you after puling it apart from the foot rests move the gear selector to "L" all the way down, lift up on both sides to clear the steering colum it will come right off, "dont worry the pastic will Flex alot you wont break it that easy'' this is the most tricky part.

3. once the plastic is removed you will need to remove the 2 metal beackets that held the plastic on, another 2 bolts, remove the air filter cover, you also are going to have to remove the clutch breather tube, "one hose clamp and it will lift right off the fuel tank".. Now time to disconect the fuel pump, there is one electrical conector to unplug, and the fuel line, I can quite remember if it's a push in type conector or a tab you need to pull out... I believe you just squeese it and push it together then pull it apart, just watch for fuel spray.

4. remove the tank you will see the pump is held in by 5 or more screws remove those screws and take the pump out.... this part can be tricky dont force it too hard you will need to turn it a bit and just wiggle it out, it will come out tho. once you have it out look at the wires make sure their conected and tight and look at this

see if it's popped out at all like this


push it together if it's not holding rlly tight wrap some thin wire arond it to hold it... thats it before you put everything back together just plug the electrical plug from the pump into the machine and see if you have your meter back if not wiggle that around a bit and see if it show's. it should work if it dont try jumping the purple wire from the pump to to ground with the machine key turned on the fuel guage should turn on... if it does your sensor in the tank is screwed try prying the contact tab in a bit to make better contact. if it still dontwok you will need a new pump. if the fuel guage dont light up when you put the purple wire to ground it's something else... but try this first... expect itto take around 2-3 hours to complete this for your first time it's not hard just time consuming.

[behrlock]

I also have a sending unit problem with mine. It reads full until about the last 1/4, then the indicator drops like a stone. One of these days I'll get around to it.

I always top up before leaving and take my Roto Pax fuel can, not just for myself but for others that I find stranded. Always good help others, never know when it'll be my turn in need of help.

Mike

[scottdeet]

Originally Posted by kent@kroekers.com

Does any one know if there is a mechanical cap-gauge that would fit this tank?

Sorry as this is a reply to an old post.
The mechanical cap wont be accurate though with the shape
of the tank. As noted in the pic, it wont let you know when the tank
is actually empty.

Here's a link to where I got a mechanical cap custom made for my `07 800 efi. Cost was $25.

the-partconnection items - Get great deals on New Snowmobile Parts, Gas Caps items on eBay Stores!

[crankybull]

On my Sportsman, the electronic gas gauge quit working and due to the nature of being upset as to why it quit working after one year. I checked with a local ex Polaris mechanic and he said happens all the time check this, check that, no luck. Well after checking everything I decided to investigate the problem myself. What did I find. Let me tell you, no electrical problems, the float in the gas tank was saturated and could not float. The kit to fix the problem cost about $150 from the dealer. I went to a boat service place, purchased a float for a gas tank, modified it to fit on my unit and presto the gauge actually works. Total cost $2.00. Taking the unit apart was about 4 hours, modification 20 minutes, assembly about 2 hours, with a couple of Bud breaks. Good luck

[fredo]

I have the same problem with the digital fuel gauge that just disappeared on my 2004 Sportsman 700 EFI. Would this be the same fix on my model?

Originally Posted by 4play

trust me, thats the first place i would check when mine did that I took the guage pod apart made sure the conections were tight, they were so i moved to the tank.... it's not hard, just time connsumeing.... this is what u do...

1. remove front rack. 4 13mm or 14mm bolts inside you can clearly see, there, 2 torqs per side by the latch and 2 under holding the fender flare's to the rack.... remove the whole front rack.

2. remove the plastic clips holding the plastic to the foot rests. remove that cover under the handle bar headlamp by pullling up on it. remove the seat. you will see 2 bolts one per side holding the plastic to 2 metal brackets remove the screws remove the gas cap. Now you can remove the plastic it helps if you get a buddy to help you after puling it apart from the foot rests move the gear selector to "L" all the way down, lift up on both sides to clear the steering colum it will come right off, "dont worry the pastic will Flex alot you wont break it that easy'' this is the most tricky part.

3. once the plastic is removed you will need to remove the 2 metal beackets that held the plastic on, another 2 bolts, remove the air filter cover, you also are going to have to remove the clutch breather tube, "one hose clamp and it will lift right off the fuel tank".. Now time to disconect the fuel pump, there is one electrical conector to unplug, and the fuel line, I can quite remember if it's a push in type conector or a tab you need to pull out... I believe you just squeese it and push it together then pull it apart, just watch for fuel spray.

4. remove the tank you will see the pump is held in by 5 or more screws remove those screws and take the pump out.... this part can be tricky dont force it too hard you will need to turn it a bit and just wiggle it out, it will come out tho. once you have it out look at the wires make sure their conected and tight and look at this

see if it's popped out at all like this


push it together if it's not holding rlly tight wrap some thin wire arond it to hold it... thats it before you put everything back together just plug the electrical plug from the pump into the machine and see if you have your meter back if not wiggle that around a bit and see if it show's. it should work if it dont try jumping the purple wire from the pump to to ground with the machine key turned on the fuel guage should turn on... if it does your sensor in the tank is screwed try prying the contact tab in a bit to make better contact. if it still dontwok you will need a new pump. if the fuel guage dont light up when you put the purple wire to ground it's something else... but try this first... expect itto take around 2-3 hours to complete this for your first time it's not hard just time consuming.

[woodrock23]

I have had the same scenario on my 500 too. I was getting inaccurate fuel readings and after refueling, the guage disappeared from the Speedo. I guess the rush of new fuel dislodged the "float" and looks like I'll be taking on this repair as well. Your instructions are very helpful and will certainly guide me along.
I'll post a follow up and give you my results after I get it working again. In the meantime, I fuel up before I go out riding each time and I can do a good day of riding before having to worry if I am going to run out.