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post #1 of 10 (permalink) Old 10-14-2014, 12:02 PM Thread Starter
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Oil Tank plastic to metal swap out

Today I changed the oil tank on my 2003 Sportsman 500 HO. I had a plastic tank that was leaking at the drain plug from an over-tweek by the previous owner. No way to repair it. I ordered an older aluminum oil tank, with all lines, on Ebay. (You can use any tank that uses the polaris part 5830053 gasket). I washed all the sludge out of it with gasoline, powerwashed it inside and out, and let it sit and drain and dry for a couple days. (I never split the tank). Then painted it with a nice high heat ceramic paint. It was pretty much a bolt in swap-out. The only alteration I had to make was to use a brass hose mender and extend the lower tank hose (which connects to the upper engine intake) by about 2-3”. Added oil, pinched off the breather for 30 seconds, and good to go. The pros are: no more leaks, far less chance of stripping out fittings, nice metal instead of plastic tank, looks nice. Cons: The oil filler is now up under the fender, which makes it a little harder to put/add oil to the tank. Easy to do and only cost me about $20. Worth every cent!
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post #2 of 10 (permalink) Old 10-14-2014, 06:22 PM
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Nice Job! Same thing is on my list for the wife's machine this winter. I have the tank just waiting for me to get to it.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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post #3 of 10 (permalink) Old 10-15-2014, 03:19 AM
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Didn't have the guts to not split my tanks. It was well worth the work considering how much sludge was left after thoroughly rinsing with diesel.
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post #4 of 10 (permalink) Old 05-26-2019, 04:03 PM
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Quote:
Originally Posted by creature_keeper View Post
Today I changed the oil tank on my 2003 Sportsman 500 HO. I had a plastic tank that was leaking at the drain plug from an over-tweek by the previous owner. No way to repair it. I ordered an older aluminum oil tank, with all lines, on Ebay. (You can use any tank that uses the polaris part 5830053 gasket). I washed all the sludge out of it with gasoline, powerwashed it inside and out, and let it sit and drain and dry for a couple days. (I never split the tank). Then painted it with a nice high heat ceramic paint. It was pretty much a bolt in swap-out. The only alteration I had to make was to use a brass hose mender and extend the lower tank hose (which connects to the upper engine intake) by about 2-3. Added oil, pinched off the breather for 30 seconds, and good to go. The pros are: no more leaks, far less chance of stripping out fittings, nice metal instead of plastic tank, looks nice. Cons: The oil filler is now up under the fender, which makes it a little harder to put/add oil to the tank. Easy to do and only cost me about $20. Worth every cent!
Please clarify the pinching off of the vent hose (top hose in the tank). I have not read this before, what is being accomplished by doing so? Is this something you do for just an oil change? Please advise, thanks
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post #5 of 10 (permalink) Old 05-26-2019, 05:33 PM
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Quote:
Originally Posted by 1948boat View Post
Quote:
Originally Posted by creature_keeper View Post
Today I changed the oil tank on my 2003 Sportsman 500 HO. I had a plastic tank that was leaking at the drain plug from an over-tweek by the previous owner. No way to repair it. I ordered an older aluminum oil tank, with all lines, on Ebay. (You can use any tank that uses the polaris part 5830053 gasket). I washed all the sludge out of it with gasoline, powerwashed it inside and out, and let it sit and drain and dry for a couple days. (I never split the tank). Then painted it with a nice high heat ceramic paint. It was pretty much a bolt in swap-out. The only alteration I had to make was to use a brass hose mender and extend the lower tank hose (which connects to the upper engine intake) by about 2-3. Added oil, pinched off the breather for 30 seconds, and good to go. The pros are: no more leaks, far less chance of stripping out fittings, nice metal instead of plastic tank, looks nice. Cons: The oil filler is now up under the fender, which makes it a little harder to put/add oil to the tank. Easy to do and only cost me about $20. Worth every cent!
Please clarify the pinching off of the vent hose (top hose in the tank). I have not read this before, what is being accomplished by doing so? Is this something you do for just an oil change? Please advise, thanks

You prime the system when you drain the oil tank and refill it.

You should also drain the crankcase.

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post #6 of 10 (permalink) Old 05-27-2019, 06:53 AM
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Just draining the oil tank you don't need to prime. If you drain the crankcase too then you will need to prime the oil pump.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
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post #7 of 10 (permalink) Old 05-27-2019, 10:53 AM
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If one is good on their maintenance frequency is draining the engine that beneficial and about how much oil is being left in the sump by not draining it?
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post #8 of 10 (permalink) Old 05-27-2019, 02:08 PM
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I am pretty religious about maintenance so I don't drain the crankcase. It leaves very little oil still in the crankcase.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2007 Sportsman 500 EFI, Polaris Winch, 26" Bear Claw HTRs on Moose 427x Wheels. QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2001 Magnum 325 Warn winch and Moose 60" plow
2017 Polaris Ranger 1000XP - Roof and front glass
SOLD 2004 Sportsman 600 Twin
stave7119 is online now  
post #9 of 10 (permalink) Old 06-07-2019, 08:30 AM
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The oil that comes out of the crankcase is usually pretty nasty even when it doesn't have that many hours.
Do what you like but I prefer to get rid of all the crud I can on every oil change.
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post #10 of 10 (permalink) Old 06-08-2019, 01:41 PM
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Got it all out, seemed like 4 oz. came out. It did take me three times priming with the vent pinched off before I heard the telltail wisp of air. All is good and the 500 is good to go this season. Now the fronend teardown of my 06 800efi sportsman.
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