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Discussion Starter #1
Need help or link to video to help me get my gas tank off my ATV. I bought it and the gas cap had a bunch of sealant around it. It was apparently cracked. I removed it and put it back on and it broke off in my hand. I assume I need a new gas tank. I bought one on ebay. They are apparently hard to find..

I found one video on youtube for a sportsman 700. It looks different than mine. I took off the seat. I took off the front plastic rack. I took off the plastic cover that is right below the headlight. I took off the side panels. I lossened all the bolts that hold on the front fender.

The snag. The front rack mounts on a metal support frame. That has to be removed somehow to get the front fender off b/c the supports go through the fender. In the video I saw of the sportsman 700 the fender could slide right off. Not the case here.

I am not sure what to loosen or take off next. Help would be greatly appreciated.
 

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Discussion Starter #2
Need help or link to video to help me get my gas tank off my ATV. I bought it and the gas cap had a bunch of sealant around it. It was apparently cracked. I removed it and put it back on and it broke off in my hand. I assume I need a new gas tank. I bought one on ebay. They are apparently hard to find..

I found one video on youtube for a sportsman 700. It looks different than mine. I took off the seat. I took off the front plastic rack. I took off the plastic cover that is right below the headlight. I took off the side panels. I lossened all the bolts that hold on the front fender.

The snag. The front rack mounts on a metal support frame. That has to be removed somehow to get the front fender off b/c the supports go through the fender. In the video I saw of the sportsman 700 the fender could slide right off. Not the case here.

I am not sure what to loosen or take off next. Help would be greatly appreciated.
Once I get the front fender off I assume I can continue working to get the gas tank out.
 

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Did mine week a or so ago, pull off the storage box, then pull the fender off, make sure the seat is off. There is a few intakes, so pull those off. And there is a little bracket that looks like a right triangle, then the fuel tank just pulls out, be careful of the fuel lines and the vacuum line.
 

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Discussion Starter #4
Digging a bit further. Would the storage box be the plastic rack in the front? I have that off. The seat is off and the side panels are off. The front fender bolts are out. The snag I have now is the support bracket that the front storage rack was mounted to is in the way. Supports for it run through the fender. I have to take that bracket off to get the fender off and expose the gas tank. The support bracket seems to have bolts that attach it to the front of the ATV by the headlights and stuff. There appear to be to additional bolts at the bottom of each side. It looks like if I loosen them I can rock the support bracket back and slip the fender off. Before I went here I want to see if I was on the right path. Also does the fender need to come off the ATV completely to get the tank? If so it looks like I need to get the fender of the handle bars/headlight. Not sure how that will work.
 

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Fuel tank removal is so basic, it is not described 'HOW TO' in the service manual.

Remove the seat, remove the front rack, rack mount, sometimes the front bumper (depends on how beat up the rack and bumper are), remove all the fasteners holding the front fender and remove the fender, then proceed to remove the tank.
 

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Discussion Starter #6
What is the easiest way to get the front rack mount off? How do I proceed to get the fender off? It looks like it needs to slide over the handle bars and headlight. The rack mount looks like it may have six bolts holding it on. Four seem to be bolts that attach it to the front bumper/headlights. Two are on the bottom and it looks like if I just loosen them I could then rotate the rack mount back which would allow me to slide the bumper over the tops of the rack mount supports. The next hurdle would then be getting the fender over the headlight and handlebars. Wish there was a video that showed how to do this.
 

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Easiest way? Get ALL the bolts out that hold it on - the handlebars do not have to be removed and the front cab do not have to be completely removed, but if you lift the cab and turn it, you can fannangle over the bars one end at a time.
140812

140813
 

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Discussion Starter #8
Thanks for the diagrams. I just bought this ATV in Jan. Never owned one. I did just change the drive belt and primary clutch. I figured it would cost a pretty penny if I took it to a shop for the gas tank. I hoped I could find some youtube videos that would walk me through it. I am proceeding slowly as nothing that I do on this thing is basic due to my lack of experience working on them. Gas tank is coming Monday so I need to get this ready this weekend.
 

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Discussion Starter #9
I got the new gas tank from power sports and got mine off yesterday. They do not match. Their part compatibility tool said it would fit but it is different. I didn't have mine out when I ordered it, I just went off the part compatibility tool they had. Mine has a fuel pump in it and theirs does not. Ugh.
 

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There is no fuel pump in the fuel tank of an 04 Sportsman 500 - there is a fuel sending unit

Don't let the 2003 on the drawing fool you - the tank is for an 04
140849

The same tank was used on:
  • 2004 A04CH42AQ SPORTSMAN 400 (A04CH42AQ/AR/AS/AT/AV) - Fuel Tank
  • 2004 A04CH50AQ SPORTSMAN 500 (A04CH50AO/AQ/AR/AS/AT/AV/AW/AX) - Fuel Tank
  • 2004 A04CH59AF SPORTSMAN 600 (A04CH59AF/AH/AJ/AT/AV) - Fuel Tank A04ch59at/Av
  • 2004 A04CH59AK SPORTSMAN 600 (A04CH59AK/AL/AN/AQ/AW) - Fuel Tank
  • 2004 A04CH68AC SPORTSMAN 700 (A04CH68AC/AF/AH/AJ/AT/AV) - Fuel Tank A04ch68at/Av
  • 2004 A04CH68AK SPORTSMAN 700 (A04CH68AK/AL/AN/AO) - Fuel Tank
  • 2006 SPORTSMAN 450 (A06MH46AA) - Fuel System A06mh46 All Options
  • 2006 SPORTSMAN 500 HO (A06MH50AA) - Fuel System /Ab/Ad/Af
  • 2006 SPORTSMAN 500 HO INTL (A06MH50FB) - Fuel System
  • 2006 SPORTSMAN 700 (A06MH68AA) - Fuel System /Ad/Af
  • 2007 SPORTSMAN 450 (A07MH46AA/AZ) - Fuel System
  • 2008 SPORTSMAN 500 HO (A08MH50AX/AZ) - Body, Fuel Tank Asm
But, there were two different Sportsman 500 in 04 - the other one used this tank
140850

It fit these models:
  • 1998 SPORTSMAN 500 (W98CH50A) - Fuel Tank
  • 1998 SPORTSMAN 500 (W98CH50AB) - Fuel Tank W98ch50a
  • 1998 SPORTSMAN 500 (W98CH50AC) - Fuel Tank S98ch50e (4950135013B002)
  • 1998 SPORTSMAN 500 (W98CH50AD) - Fuel Tank S98ch50e (4950135013B002)
  • 1998 SPORTSMAN 500 (W98CH50AE) - Fuel Tank S98ch50e (4950135013B002)
  • 1998 SPORTSMAN 500 (W98CH50AF) - Fuel Tank S98ch50e (4950135013B002)
  • 1998 SWEDISH SPORTSMAN 500 (S98CH50E) - Fuel Tank (4950135013B002)
  • 1998 SWEDISH SPORTSMAN 500 (S98CH50EB) - Fuel Tank S98ch50e (4950135013B002)
  • 1999 SPORTSMAN 500 (A99CH50AA) - Fuel Tank A99ch50eb
  • 1999 SPORTSMAN 500 (A99CH50AB) - Fuel Tank A99ch50eb
  • 1999 SPORTSMAN 500 RSE (A99CH50AC) - Fuel Tank
  • 1999 WORKER 500 (A99CH50EA) - Fuel Tank A99ch50eb
  • 1999 WORKER 500 (A99CH50EB) - Fuel Tank
  • 2000 SPORTSMAN 500 (A00CH50AA) - Fuel Tank
  • 2000 SPORTSMAN 500 (A00CH50AB) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 (A00CH50AE) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 (A00CH50AF) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 (A00CH50AH) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 (A00CH50AK) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 (A00CH50AL) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 (A00CH50EB) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 RSE (A00CH50AC) - Fuel Tank A00ch50aa
  • 2000 SPORTSMAN 500 RSE (A00CH50AJ) - Fuel Tank A00ch50aa
  • 2001 SPORTSMAN 400 (A01CH42AA) - Fuel Tank
  • 2001 SPORTSMAN 400 (A01CH42AB) - Fuel Tank A01ch42aa
  • 2001 SPORTSMAN 400 (A01CH42AC) - Fuel Tank A01ch42aa
  • 2001 SPORTSMAN 500 DUSE (A01CH50AD) - Fuel Tank
  • 2001 SPORTSMAN 500 DUSE HO (A01CH50AF) - Fuel Tank A01ch50aa
  • 2001 SPORTSMAN 500 HO (A01CH50AA) - Fuel Tank
  • 2001 SPORTSMAN 500 HO (A01CH50AB) - Fuel Tank A01ch50aa
  • 2001 SPORTSMAN 500 HO (A01CH50AE) - Fuel Tank A01ch50aa
  • 2001 SPORTSMAN 500 HO (A01CH50AK) - Fuel Tank A01ch50aa
  • 2001 SPORTSMAN 500 RSE HO (A01CH50AJ) - Fuel Tank A01ch50aa
  • 2001 WORKER 500 (A01CH50EB) - Fuel Tank A01ch50aa
  • 2002 SPORTSMAN 400 (A02CH42AA) - Fuel Tank
  • 2002 SPORTSMAN 400 (A02CH42AB) - Fuel Tank A02ch42aa
  • 2002 SPORTSMAN 400 (A02CH42AC) - Fuel Tank A02ch42aa
  • 2002 SPORTSMAN 500 ALL OPTIONS (A02CH50) - Fuel Tank All Options
  • 2003 SPORTSMAN 400 (A03CH42AA/AB/AC) - Fuel Tank
  • 2003 SPORTSMAN 500 HO (A03CH50AA/AB/AC/AD/AE/AH/AJ) - Fuel Tank
  • 2004 A04CH42AA SPORTSMAN 400 (A04CH42AA/AE/AG) - Fuel Tank
  • 2004 A04CH50AA SPORTSMAN 500 (A04CH50AA/AC/AE/AG) - Fuel Tank
  • 2004 A04CH42AA SPORTSMAN 400 (A04CH42AA/AE/AG) - Fuel Tank
  • 2004 A04CH50AA SPORTSMAN 500 (A04CH50AA/AC/AE/AG) - Fuel Tank
That's why the parts guy asks for the VIN or model number when you order parts - WHICH MODEL DO YOU HAVE?
 

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Discussion Starter #11
Paperwork says: 04 Polaris Sportsman 500 Red
Class A
VIN: 4xach50a64b146125

My gas tank had a circular metal object in it that the one I purchased does not have. Probably the sending unit like you mention. My gas tank also has one tube out of the bottom and the one I bought has two. I assume that I can't use the one I got because it doesn't have the sending unit?
 

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Just a little helpful advice OP... Ask ALL the pertinent questions BEFORE you order parts. The guys on here will steer you to the correct parts if you just ask beforehand. We can often save you some money while doing it too.
 

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By the VIN, you have a late 04 - actually an 04.5, but the model is more important - model A04CH50AW-

Model Name - SPORTSMAN 500 HO RED '04.5
Model Year - 2004
Model Number - A04CH50AW
Purchase Date - 12/26/2003
VIN - 4XACH50A64B146125
Engine Serial Number - D006370410359

It was supposed to be the tank with the sending unit and the frames are different so the tanks can't be interchanged - you are going to have to get the right one.

The tank you bought fits models A04CH50AA/AC/AE/AG
The tank you need is for models A04CH50AO/AQ/AR/AS/AT/AV/AW/AX
 

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Discussion Starter #14
Thanks for the information. I emailed the company and called and left them a voice message. Hopefully they have a tank I can use and will take the old one back. If they don't have one, do you have any idea where I can get one?
 

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Discussion Starter #16
Yikes! I paid $140 for the one they sent me. I hope they have the right one and we can do an even exchange.
 
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