your float is sticking down most likely make sure the float hasnt cam off the arm also.Only way to get a new sending unit from polaris is to replace the pump/tank asm.thats about 450.00 or so.

 

if it comes to that. and it has no warranty. take the sending unit out, and bring it to an automotive place parts place like napa or car quest or and o'reilly's autoparts store and match it for ya. you can get one there for around $100 the same pump i beleve was used in a 90ish yr toyota pickup or something like that.

 

Thanks Mongral and Chuck R. Chuck R., my 500 is a efi, but I would like to see the photos you made of your sensor. I bet they are the same, and if not, at least it gives me an idea of what I am looking for. How did you get the sensor out of the tank? Sewnd the phots to fzorn1@aol.com if possible...
Mongral, I will give this a try if all else fails...thanks for the info..... Fred

 

Thanks Ramman67.. I am diligently working on this problem...Have you ever taken the float out of the tank?? How is it done??

Thanks,, Fred

 

I have taken a few apart. take front box off then front fenders to get to the tank then you can get to the tank.We usally take a stiff wire and look in the tank with a flash light and pick up on the float arm with the wire to see if that changes your fuel level reading.If tanks very full you will need to drain your tank down some pumps in right front corner of the tank.So look toward the front of the tank for the arm.

 

here ya go:







hope this helps some what for ya.

 

you will also need to remove clutch cover out let tubethat runs over top of tank.Your pump most likely will have screws holding the pump in the tank take them out and lift pump asm up and out of tank.some of the newer tanks have a lock ring that unscrews that holds pump in the tank.