2006 Sportsman EFI Fuel Guage

[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

[Bruce!]

First off, Welcome to the board!

[blueline15]

the fuel gauge should be 6 little boxes and the right of the electronic display. they should always be showing, whenever the machine is on.

and no, you do not have a fuel valve or reserve switch. your fuel pump is housed inside the fuel tank, and being an EFI, the fuel system runs on a certain pressure. you dont need a reserve switch because you are supposed to have a fuel gauge, and you dont really need to turn the fuel flow off, as fuel can not leak out with the pump being internal, no carb, and no external fuel pump

[gfyoung3]

This is what I thought based on the owner's manual. However, nothing shows up on the right hand side of the display as shown on the manual.

Originally Posted by blueline15

the fuel gauge should be 6 little boxes and the right of the electronic display. they should always be showing, whenever the machine is on.

and no, you do not have a fuel valve or reserve switch. your fuel pump is housed inside the fuel tank, and being an EFI, the fuel system runs on a certain pressure. you dont need a reserve switch because you are supposed to have a fuel gauge, and you dont really need to turn the fuel flow off, as fuel can not leak out with the pump being internal, no carb, and no external fuel pump

[blueline15]

the speedo unit itself might be bad...let me do some checking

[4play]

what more then likely hapened... "its happend to mine" same thing it just disapears, and this is how you fix it. remove the fuel tank take out the pump, be carefull you will have to wiggle it and turn it to get it out but onnce you get it out you will see the float " a black thing on a metal rod that gos up and down.. looks like something that's in your toilet lol, anyway, you will see up where it attaches to the pump it clips tight to the pump assy, and that's where the potentiometer is for the fuel guage, it came unclipped and is no longer touching that fuel guage sensor clip it back in and get some mechanic's wire and use needle nose plyers and wrap and twist it tight so it dont pop out again. fixed. just make sure that thing goes up and down freely and that your wire tie job dont hit anywhere..... and yes i advise you to wrap it otherwise a few good bumps later you will have to tear it apart again.

[gfyoung3]

This maybe a little above my head - I'm not the most mechanically inclined. I looked at this again last night. Even when I first turn the key on, when the digital display lights up and all the electronic read outs are showing - there is nothing where the fuel guage should be. Do you think it could still be the issue below?

Thanks for the help.

Originally Posted by 4play

what more then likely hapened... "its happend to mine" same thing it just disapears, and this is how you fix it. remove the fuel tank take out the pump, be carefull you will have to wiggle it and turn it to get it out but onnce you get it out you will see the float " a black thing on a metal rod that gos up and down.. looks like something that's in your toilet lol, anyway, you will see up where it attaches to the pump it clips tight to the pump assy, and that's where the potentiometer is for the fuel guage, it came unclipped and is no longer touching that fuel guage sensor clip it back in and get some mechanic's wire and use needle nose plyers and wrap and twist it tight so it dont pop out again. fixed. just make sure that thing goes up and down freely and that your wire tie job dont hit anywhere..... and yes i advise you to wrap it otherwise a few good bumps later you will have to tear it apart again.

[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.

[gfyoung3]

4play- Thanks for the directions and pics. I may give it try down the road.

What kind of fuel mileage can I expect to get out of a tank of gas? I'm sure this varies on the riding style. Just looking for some info on when I should be refueling until I get the gauge working.

Thanks

[blueline15]

probably dont want to go further the 60-80 miles without refueling.