Fuel Sender Unit Mystery

For the past few years my fuel gauge has read empty on my '08 Sportsman 800. I just thought the float was detached. and never got around to fixing. Well today I pulled the gas tank (need to change spark plugs.) and took off the fuel sender unit.

Sender unit looks good, float is undamaged and attached. I cleaned up the resistor pad with some scotch bright pad - but still it don't work. If I plug in the sender unit outside of the tank and manually move the float value it works. Yet when I install in the tank and fill with gas, I'm only get an empty reading.

A new sender unit is $450 so that's not an option.

I'm stuck on why this fuel float sender is not working properly

Any suggestions?

Fuel Sender Unit Mystery

For the past few years my fuel gauge has read empty on my '08 Sportsman 800. I just thought the float was detached. and never got around to fixing. Well today I pulled the gas tank (need to change spark plugs.) and took off the fuel sender unit.

Sender unit looks good, float is undamaged and attached. I cleaned up the resistor pad with some scotch bright pad - but still it don't work. If I plug in the sender unit outside of the tank and manually move the float value it works. Yet when I install in the tank and fill with gas, I'm only get an empty reading.

A new sender unit is $450 so that's not an option.

I'm stuck on why this fuel float sender is not working properly

Any suggestions?

2010 Ranger 800 EFI – many issues solved, some to go…

Recently purchased a 2010 Ranger Crew 800 knowing that it would not run (it would turn over but not fire). I was told the battery was charged backwards, and then a new battery installed, but wouldn’t run from then on. Before that happened, it ran. I went through many things hoping that it wasn’t an Ecu (replaced spark plugs, CDI/coil) but ultimately a new ProCom programmable Ecu controller that seems to solve the problems - it fires right up. BUT now, after about 30-45sec of running, what smells like gas seeps out around the reed valve (fitting on top of the rocker cover) where a hose goes back to the air filter housing - and it shuts down. Then it won’t start for hours after. I’ve checked compression and it’s about 130-140psi & the fuel pressure is 39psi. The seal around the air filter access cover is missing. The air filter is wet with fuel. The coolant and engine oil all look good. I’m guessing it may still be electrical/sensor related, but also thought it could be valve seats/seals, but I’ve never ripped into these engines before and didn’t want to go exploring. Any one have thoughts on this? Air sensor or throttle sensor? I appreciate your help and promise to post the fix once I / we get it solved. Thanks!! Dan

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