M
Mech Engr
Well-known member
My fuel gauge on my 2005 RMK 900 was working when the tank was full but after 10-20 miles it would read empty. When I first got the sled it was like this so I pulled the tank and found that the contacts on the sending unit were simply not making contact. I bent the contacts back in place and went almost the entire season (800 miles) before it started doing it again. I purchased the float kit but that has nothing to do with the problem and my sled already had the updated float.
I was looking up some parts one day and found that there is a sending unit kit available through Polaris. Not every online parts house lists them for some reason but Polaris Pit Stop does. The part number is 2877700 and it costs about $18 retail. The contents of the kit are shown below. I also took a few pics of the replacement/repair. Basically, you remove the tank, remove the pump/pick-up/gauge unit from the tank, remove the float and arm, remove the black housing by pushing the stamped metal tab down and sliding the housing out, removing the small circuit board (snaps in and out), de-soldering the purple/white wire from the board, soldering the purple wire to the new board and snapping the board back in the new housing from the kit, assembling the float arm and white retainer with a new contact from the kit, installing the housing and bending back the metal tab to hold it in place making sure to route the wires as seen in the picture to avoid the float arm, reinstalling the arm/float assembly with the new black retainer, installing the pump, pick-up/gauge back in the tank and installing the tank back in the sled. I don’t believe these kits have been available in the past.
Hope this will get posted in the “How to” section.
Oh, P.S. I got two contacts in my kit for some reason but you only need one.
John
I was looking up some parts one day and found that there is a sending unit kit available through Polaris. Not every online parts house lists them for some reason but Polaris Pit Stop does. The part number is 2877700 and it costs about $18 retail. The contents of the kit are shown below. I also took a few pics of the replacement/repair. Basically, you remove the tank, remove the pump/pick-up/gauge unit from the tank, remove the float and arm, remove the black housing by pushing the stamped metal tab down and sliding the housing out, removing the small circuit board (snaps in and out), de-soldering the purple/white wire from the board, soldering the purple wire to the new board and snapping the board back in the new housing from the kit, assembling the float arm and white retainer with a new contact from the kit, installing the housing and bending back the metal tab to hold it in place making sure to route the wires as seen in the picture to avoid the float arm, reinstalling the arm/float assembly with the new black retainer, installing the pump, pick-up/gauge back in the tank and installing the tank back in the sled. I don’t believe these kits have been available in the past.
Hope this will get posted in the “How to” section.
Oh, P.S. I got two contacts in my kit for some reason but you only need one.
John
