Fuel Sender Service; Troubleshooting - Polaris SPORTSMAN 600 Service Manual

LATE 2004 FUEL SENDER
REMOVAL/INSTALL
Fuel Sender Removal
1. Disconnect the negative battery cable.
2. Remove the side panels and front cab assembly.
Refer to "COVER PANEL REMOVAL" in Chapter
5 for details.
3. Remove the gas tank cover vent hose. Be sure to
properly route the vent hose upon reassembly.
Pic 1
4. Remove the clamps on the PVT intake duct and
remove the PVT duct.
5. With all the body panels removed from the front of
the ATV and the gas tank exposed, disconnect
the fuel sender wiring harness.
6. Remove the 5 screws that secure the fuel sender
to the tank.
FUEL SYSTEM/CARBURETION
7. Slowly lift the sender out of the tank. Lift the
sender out at an angle, so the float will more easily
come out of the fuel tank.
Fuel Sender Installation
1. Reinstall the fuel send and a new gasket.
2. Install the 5 screws and torque the screws to
18--24 in.lbs. (2--3 Nm) in a criss--cross pattern.
Reconnect the sender wiring harness and route
the harness properly.
3. Reinstall the PVT intake duct, gas tank vent line,
front cab assembly, and side panels.
NOTE: Properly route the gas tank vent line, use tape
to secure the vent line in place. (See Pic 1).
4. Reconnect the negative battery cable. Test the
sender for proper operation.
FUEL SENDER

TROUBLESHOOTING

Refer to Chapter 10 for fuel sender troubleshooting.
4.13