2004 600 sportsman fuel gauge
 

My sportsman was missing the fuel sending unit on top of the tank when I got it.just got a new one today and installed it. Tank was almost empty and the gauge read empty. I put about half a tank in and now it shows full and doesn't move from there. The floor moves free. Do they need to be calibrated somehow?

These sending units were not that accurate because a lot of the tank is below the frame.Many showed full when you still had room in the tank. If the float isn't hitting the side of the tank you might have to bend the wire up a little so the float can show a more accurate reading.Also when they got older floats would become saturated and show empty on full tanks. Replacement floats are available for these.

I suggest never trusting a fuel gauge-lol Over the years I've learned to always top my rides off before hitting the trail and carry extra. Also keep a mental note on how far you can ride on a tank so you don't get in a jam.

The ones on my Arctic Cats were useless, ethanol gas would destroy the plastic bezel and the floats would absorb gas and sink. I went to a machine shop and had 2 aluminum plugs made to plug the holes. I wouldn't be surprised that the Polaris float will be attacked by ethanol in time.

They all are after a period of time. John Deere has replacements for Polaris atvs,Rzrs, Can am and Arctic cat for people that still want a gauge whether it's accurate or not.FUEL GAUGE SENDING UNIT FLOAT - Polaris ATV - X2, Sportsman 500, 700, 800, Can-Am Renegade - DJSFLOAT