2009 Polaris Sportsman 800 EFI - Polaris ATV Forum
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post #1 of 12 (permalink) Old 04-22-2010, 02:04 PM Thread Starter
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2009 Polaris Sportsman 800 EFI


Specifications

Polaris Sportsman Engine
Starter : Electric
Compression Ratio : 10:1
Displacement (cc) : 760
Engine Stroke : 4-Stroke
Cylinders : 2
Engine Type : Twin Cylinders

Polaris Sportsman Transmission
Reverse : Yes
Primary Drive (Rear Wheel) : Shaft
Transmission Type : Continuously Variable (CVT)

Polaris Sportsman Weight
Dry Weight (lbs) : 770
Towing Capacity (lbs) : 1500

Polaris Sportsman Dimensions
Height (in) : 48
Wheelbase (in) : 50.8
Ground Clearance (in) : 11.3
Width (in) : 48
Length (in) : 83

Polaris Sportsman Driveline
Rear Unlocking Differential : No
Driveline Type : Selectable 4X2 / 4X4

Polaris Sportsman Capacities
Fuel Capacity (gal) : 4.1

Polaris Sportsman Front Suspension
Front Travel (in) : 8.2
Front Suspension Type : McPherson Strut

Polaris Sportsman Rear Suspension
Rear Travel (in) : 9.5
Rear Suspension Type : Independent

Polaris Sportsman Seat Specifications
Seat Height (in) : 34
Number Of Seats : 1

Polaris Sportsman Brakes
Rear Brake Type : Hydraulic Disc
Front Brake Type : Hydraulic Disc

Polaris Sportsman Tires
Rear Tire (Full Spec) : 26 X 11-12 PXT
Front Tire (Full Spec) : 26 X 8-12 PXT

Polaris Sportsman Price
MSRP : $7999
Warranty (Months) : 6
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post #2 of 12 (permalink) Old 07-07-2014, 10:07 AM
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Hello try this again
I have a 2009 Polaris sportsman 800. The fuel gauge reads almost empty when tank is full. Pulled pump and sensor out of tank and moved float up and down and fuel gauge moved accordingly. Found out float is absorbing gas which is causing it to sink in the gas tank which is giving a false reading. Call dealer and was told I had to buy complete tank for $502 so I could fix the problem of a $5 part. Why are so many people having the same problem and why are you making the ones that want it fixed right pay an so much when it seems like it is a manufacturer's defect and should be recalled for faulty float.
Looks like I will be wiring mine up like everyone else is doing that doesn't want to taken to the cleaners.
Thank you for your time
Rick Castle
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post #3 of 12 (permalink) Old 07-09-2014, 05:37 PM
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My 2008 has had the same issue since I bought it 3 years ago. I bit the bullet and paid the price to do the tank and whole unit. Finally works. Expensive but works.

Sent from my SCH-I545 using Tapatalk

Jim


2008 Sportsman 500 Touring EFI
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post #4 of 12 (permalink) Old 07-10-2014, 02:18 AM
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I had the same issue myself.
I did a search here and found a link to a site that sells replace me t floats. It's a tractor shop called DJ supply or something like that and the float is for an Allis Chalmers tractor.
I paid $16 including shipping and just replaced the float.
Works perfectly now.
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post #5 of 12 (permalink) Old 07-18-2014, 02:55 AM
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How did you attach new float?

2007 Sportsman 800
1500 miles, mostly at Hatfield-McCoy trails, WVa.
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post #6 of 12 (permalink) Old 07-18-2014, 03:31 AM
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Float

Hello
I just removed my float and wired the plastic piece up whre it showes a 1/4 of a tank always.
Rick
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post #7 of 12 (permalink) Old 07-18-2014, 04:04 AM
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I installed a new float. I ended up threading the end of the float rod using 4-40 machine thread die. Then double nutted the float on using brass nuts.

I was wondering what others did or used when replacing their floats.

2007 Sportsman 800
1500 miles, mostly at Hatfield-McCoy trails, WVa.
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post #8 of 12 (permalink) Old 07-18-2014, 04:38 AM
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The new float I bought came with a slide on retainer ring. I don't know the technical term but it's a slotted flat washer that is just slightly smaller than the rod and holds on with spring tension.
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post #9 of 12 (permalink) Old 07-18-2014, 04:51 AM
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I bought my new float from DJS Tractor. It came with a washer, thats all. It was a bit too big for the rod and would not have held anything on. I looked locally for what you are describing,...it is a "push on retainer" nut but could not find one in Stainless. Which is a MUST given the nonavailability of non alcohol fuels regionally. Have to use stainless or brass, otherwise it will rust/corrode eventually, and I don't want to have to do this again given the choice.

Thanks.

2007 Sportsman 800
1500 miles, mostly at Hatfield-McCoy trails, WVa.

Last edited by WalterS; 07-18-2014 at 04:53 AM.
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post #10 of 12 (permalink) Old 07-18-2014, 05:24 AM
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Were you possibly able to save the retaining washer that was on there? I've had to do that in the past.
If not, you can do as WalterS suggested by threading the rod and putting on a nut.
You might even get lucky and find a self tapping nut.

Remember, there isn't going to be a whole lot of strain on this part. The only outside force will be vibration.
It might even be possible to slip the new washer on and then "crushing" the end of the rod with a pair of really strong vise grips.
It won't take much to keep this from sliding off the end of the rod.
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