Well guys, My fuel gauge would only go to about 3/4 full when it was full...
So I let it go... wasn't worth a second look...
Then last week it wouldn't get above 1/2 tank...
So I searched the internet to try and find a solution..
I came up the float arm or float was sticking to the side of the tank...
Use a metal clothes hanger to bend it up a little...
Don't put a hanger in the tank unless you have a mirror to see what you are doing...
I ended up pulling the float arm away from the assembly and getting an error and no fuel gauge. I ended up taking the tank off and removing the pump assembly... fixing the arm and bending it a little upward to see if I could free it from touching.. no luck... dumped fuel out again... and again... and again... and again... until I was fed up with the process..
I took it to the dealer in the morning and he confirmed the sending unit was working properly and I was installing it back in the tank correctly. He also told me that they had come out with a pump assembly now instead of a whole tank assembly... I asked him if he had any pumps that I could compare mine too and he only has a Ranger fuel tank with a fuel pump assembly still in.. He gave me the pump and I took it home and found out the float on my assembly was heavier than it should have been. Changed te float and bent it a little to get the right reading...Everything works great and I hope this helps someone out.

Jon

 

in the late 08' 800's they said they changed the fuel pump assembly so that you could just replace the sending unitl/pump w/ out having to buy the whole tank. my gauge on my 800 would sometimes be 1 bar down when i was full, but later on went to a full reading after riding a little.