Ameer Randolph
If you're looking to remove the fuel tank from a 2004 Polaris Sportsman, there are a few steps you'll need to take. Firstly, it's important to allow the engine and exhaust to cool completely before beginning any work. You'll then need to remove the seat, the side panels, and the front fender bolts. Be cautious when handling the fuel lines and vacuum line, and pay attention to the support bracket that the front storage rack is mounted to, as this may need to be removed to access the fuel tank. While there are YouTube videos available for removing the fuel tank from a Polaris Sportsman 700, the process may differ for your model, so proceed with caution.
| Characteristics | Values |
|---|---|
| Vehicle | 2004 Polaris Sportsman 500 ATV |
| Fuel pump | There is no fuel pump in the fuel tank, only a fuel sending unit |
| Fuel gauge | Not mentioned in sources |
| Fuel filter | Replace the fuel filter after removing the fuel tank |
| Fuel venting | Check for fuel venting problems |
| Fuel line | Disconnect the fuel line at the fuel rail |
| Fuel pressure | Open the relief valve and release the fuel pressure |
| Fuel tank finish | Protect the fuel tank finish when removing, storing, and installing the tank |
| Fuel tank removal | Unbolt the front cab, remove the air duct, and lift the tank up and out |
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What You'll Learn
Check for blocked fuel lines/filters
To check for blocked fuel lines/filters on a 2004 Polaris Sportsman, follow these steps:
Begin by locating the fuel lines and filters. The fuel lines are usually located between the fuel tank and the engine, while the fuel filter is typically situated along the fuel line.
Once you have located the fuel lines and filter, inspect them for any signs of blockage or obstruction. Look for any visible debris, dirt, or rust that may be blocking the fuel line or filter. You may need to use a flashlight to get a better view.
If the fuel filter appears dirty or clogged, it will need to be replaced. The fuel lines can be cleared of any debris or dirt by gently blowing compressed air through them. Ensure that you are wearing appropriate safety gear, including gloves and eye protection, when handling fuel lines and filters.
To prevent future blockages, it is recommended to regularly inspect and replace the fuel filter as part of your ATV's maintenance routine. Refer to your Polaris Sportsman service manual for specific recommendations regarding fuel filter replacement intervals and procedures.
By following these steps, you can effectively check for and address any blockages in the fuel lines and filter of your 2004 Polaris Sportsman.
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Disconnect the fuel line
To disconnect the fuel line of a 2004 Polaris Sportsman, you must first remove the seat, the front rack, the rack mount, and the front bumper. Then, remove all the fasteners holding the front fender and remove the fender. There are a few intakes, so make sure to pull those off as well. Be careful of the fuel lines and the vacuum line.
Once you have exposed the fuel tank, you will need to remove the fuel line from the fuel valve on the tank bottom. Be very careful not to damage the fuel valve.
If your main purpose for accessing the tank is to reach the plug, you may not need to remove the tank. Instead, you can reach up from the front of the engine, pop the plug cap off, and use a short 13/16" box wrench to access the plug.
It is important to note that the process of removing the fuel tank from a 2004 Polaris Sportsman is not considered complex, as it is not described in the "HOW TO" section of the service manual.
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Remove the seat
To remove the seat of a Polaris Sportsman, you must first remove the side panel. Remove the fasteners securing the side panel to the frame and then lift the right side. Once the side panel is removed, you can remove the seat. It appears that the seat back is easy to remove, with the seat pegs engaging into the base of the seat back.
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Drain the fuel tank
To drain the fuel tank of a Polaris Sportsman, you will first need to remove the fuel tank. This will involve the following steps:
- Unbolt the front cab (plastic) and remove or lift it high enough to access the tank underneath.
- Remove the air duct or clutch air tube, as the tank usually catches on this.
- Disconnect the fuel line from the fuel valve at the bottom of the tank, being careful not to damage the valve.
Once the tank has been removed, you can drain the fuel by:
- Removing the hose clamp on the fuel line from the tank, at the valve, or removing the covers and then removing the fuel tank.
- Using a siphon hose to get to the lowest point in the tank and remove any foreign substances.
- Treating the fuel in the tank with a product like Stabile and leaving it alone, or running the engine for a few minutes.
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Lift the console up and out
To remove the fuel tank from a 2004 Polaris Sportsman, you must first remove the seat, the front rack, the rack mount, and sometimes the front bumper. Next, remove all the fasteners holding the front fender, and then remove the fender.
Now, to lift the console up and out, away from the fuel tank, you must first lift the rear of the console enough to clear the fuel cap. Then, push forward to release the front mount from the keyway.
It is important to note that you should not use anything other than your fingers to remove the quick connection, as tools can damage the connection.
Once the console is lifted, you can complete the fuel tank removal by following the remaining steps outlined in the Polaris Online Publication Portal, which include disconnecting fuel lines and removing various parts.
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Frequently asked questions
You can start by removing the seat, the side panels, and the front fender bolts.
You will need to remove the support bracket that the front storage rack is mounted on. This is because the supports run through the fender.
Once you have removed the support bracket, you can lift the rear of the tank and pull it rearward to remove it. Make sure you place it in a secure location with a drain pan to catch any fuel leaks.
