Doesn't happen often on tank necks cracking,but glad you found the problem.

 

Thanks installed the replacement tank yesterday.A new one was not available so i bought the best looking replacement tank i could find on ebay.It is suppose to be the superseded part number tank which is not available.anyway its a white clear tank with srew in fittings.The original tank is black with fittings that pull out of rubber tank seals.But its a great clean leak free tank and i put new fuel lines on it so all has worked out great

 

A gas tank is sure a uncommon part to fail.

Is it the 5.25 Gallon or the 4.75? Polaris kept making their tanks smaller and smaller. http://www.atvreviewnetwork.com/enth...le2=3395&go=Go Their 800 Sportsman had a small 4 gallon tank.

 

I dont know to be honest.I suppose it could be a 5.25 tank i have now.And the black one was 4.75. My thoughts are this tank is from a older machine than 2004

 

Mine is the 5.25 and is clear, does the new one look to have the mounts in the same place as the old?
May or may not be a problem if the tanks for a Gen IV chassis (2003 and down) The 2004 was a Gen VI Chassis. Polaris Generation Chart. But the 2003 400 Sportsman Gen IV also had the Gen VI 4.75 2003 Polaris Sportsman 400 ATVs so the 5.25 may fit.

 

Yes looked like all was the same on it.Although a increase of .5 gals in size may be hard to tell.It fit perfect in the ATV.I am assumeing it must be the older 5.25 tank.A chart i saw showed that tank fitting a lot of atvs up to 400 and 500 sportsman

 

0.5 may not sound like much but that almost 10 miles less walking then the other guy if you both run out of gas.LOL

 

"It is suppose to be the superseded part number tank which is not available.anyway its a white clear tank with srew in fittings.The original tank is black with fittings that pull out of rubber tank."

The tank grommets and inserts sucked! Believe me you got the better tank with the screw in tank fittings.Had to update these grommets with "improved ones"when they leaked,nasty job..Another reason I'm glad I'm retired..