I have an 06 Sportsman 800 that i bought used 2 years ago. From day 1 it always had a strong odor of gasoline while riding as if there was a leak but could never find one, Now, just recently when i fill the gas tank to the top, it will not read a full tank, it reads 2 bars below full?

 

Check the tank vent tube that terminates under the headlight pod area for any kinking.Gas bubbles would collect around some of the tubes that had those crappy one way check valves in the vent lines. I got rid of some and made sure the lines went up so gas wouldn't collect and smell. Might not be a bad idle to check the quick connects on the fuel filter up front also for any leakage and change the filter if it's been awhile. DJS Tractor supply has replacement floats as some were prone to become saturated and threw fuel level off.FUEL GAUGE SENDING UNIT FLOAT - Polaris ATV - X2, Sportsman 500, 700, 800, Can-Am Renegade - DJSFLOAT If you're going to all that trouble I'd go ahead and replace the pump while you're there and be done with it. Pump kits are between 16-18 bucks on amazon and ebay and include new tank strainers.

 

Ditto on OPT's post. Also, don't worry about fuel level readings. I never trust them on any machine. Always better to check by looking in the tank. The more you ride it the more you'll get a feel for how far a tank will last. Doesn't hurt to always carry extra-there are some nice options for fuel carriers out there.