Let’s be honest. That cracked, leaking, or sun-faded gas tank on your Polaris Predator 500 isn’t just an eyesore—it’s a ride-ending problem waiting to happen. A faulty tank can leave you stranded, damage your engine, and poses a serious safety risk.
You’ve come to the right place. We promise this comprehensive guide will give you the confidence and know-how to tackle this job yourself, saving you a trip to the shop and getting you back on the trail fast.
In this article, we’ll walk you through everything from identifying the need for a polaris predator 500 gas tank replacement to the final bolt. We’ll cover the tools you need, a detailed step-by-step installation process, pro tips to avoid common mistakes, and how to care for your new tank.
Why a Polaris Predator 500 Gas Tank Replacement is a Smart Upgrade
Replacing your ATV’s gas tank might seem like a major task, but the reasons for doing it go far beyond simple cosmetics. Understanding the benefits of polaris predator 500 gas tank replacement makes it clear why this is a crucial piece of maintenance.
Enhanced Safety on the Trail
This is the big one. The original plastic tanks on the Predator 500 are known to become brittle over time due to UV exposure and age. This can lead to stress cracks, especially around the mounting points.
A leaking fuel tank is an extreme fire hazard. Gasoline dripping onto a hot engine or exhaust is a recipe for disaster. A new tank eliminates this risk, giving you peace of mind on every ride.
Preventing Costly Engine Damage
Cracks don’t just let fuel out; they let contaminants in. Water, dirt, and debris can enter a compromised tank, bypassing the fuel filter and making their way into your carburetor or fuel injection system.
This contamination can clog jets, damage fuel pumps, and lead to poor performance, stalling, and eventually, a costly engine rebuild. A fresh, sealed tank is the first line of defense for your engine’s fuel system.
Restoring Performance and Aesthetics
A faded, yellowed tank makes an otherwise great-looking quad look old and neglected. A new tank instantly revitalizes the appearance of your Predator.
Furthermore, a clean tank ensures a consistent, clean fuel supply, which is essential for your engine to perform at its peak. You’ll avoid the sputtering and hesitation that can come from a contaminated fuel source.
Gearing Up: Tools and Parts You’ll Need
Before you start spinning wrenches, a little preparation goes a long way. Having the right tools and parts on hand makes the job smoother and safer. Here’s your checklist.
Essential Tools
- Socket Set: A basic metric socket set (8mm, 10mm, 12mm are common) with a ratchet and extension.
- Wrenches: A set of metric combination wrenches.
- Siphon Pump or Hose: To safely drain the old fuel from the tank.
- Fuel-Safe Container: A certified gas can to store the drained fuel.
- Pliers: Needle-nose and standard pliers for fuel line clamps.
- Shop Rags or Towels: For cleaning up inevitable fuel spills.
- Safety Gear: Mandatory! Nitrile gloves and safety glasses are non-negotiable.
Required Parts
- New Gas Tank: Either an OEM replacement or a quality aftermarket option.
- New Fuel Petcock (Recommended): It’s cheap insurance. The old one might be clogged or have failing seals.
- Thread Sealant: A gasoline-resistant thread sealant for installing the new petcock.
- New Fuel Line (Recommended): Old fuel lines can be brittle and prone to cracking. Replace it while you have easy access.
- New Hose Clamps: Don’t reuse old, stretched-out clamps.
The Complete Polaris Predator 500 Gas Tank Replacement Guide
Alright, you’ve got your gear. Now it’s time for the main event. This detailed polaris predator 500 gas tank replacement guide breaks the process down into simple, manageable steps. Work slowly, be methodical, and prioritize safety above all else.
Step 1: Safety First – Prep Your Workspace
Work in a well-ventilated area, like an open garage or outdoors. Gasoline fumes are highly flammable. Ensure there are no open flames, sparks, or sources of ignition nearby (like water heaters or space heaters). Disconnect the negative terminal on your ATV’s battery as an extra precaution.
Step 2: Drain the Old Fuel
Turn the fuel petcock to the “OFF” position. Use your siphon pump to carefully transfer all the fuel from the old tank into your approved fuel-safe container. Take your time to avoid spills.
Step 3: Remove the Seat and Plastics
The seat typically unlatches from the rear. Next, remove the front plastics (fenders and “hood” area). This usually involves removing a few 8mm or 10mm bolts and push-pins. This will give you clear access to the gas tank and its mounting points.
Step 4: Disconnect the Fuel Line
Place a shop rag under the fuel petcock to catch any residual fuel. Use pliers to slide the hose clamp off the petcock’s nozzle, then gently twist and pull the fuel line off. Be prepared for a small amount of gas to drain out.
Step 5: Unbolt and Remove the Old Tank
The Predator 500 tank is typically held in place by a mounting strap or bolts at the front and rear. Locate these bolts (usually 10mm or 12mm) and remove them. Once unbolted, you can lift the old tank straight up and off the frame.
Step 6: Prep the New Tank
If your new tank didn’t come with a petcock, you’ll need to install one. Wrap the threads of the new petcock with your gas-resistant thread sealant and screw it into the new tank. Tighten it until it’s snug, but do not overtighten, as you can crack the plastic.
Step 7: Install the New Gas Tank
Carefully lower the new tank into position on the frame, making sure it sits correctly on the rubber mounting grommets. Re-install the mounting bolts or strap and tighten them securely.
Step 8: Reconnect Everything
Slide a new hose clamp onto your new fuel line. Push the fuel line firmly onto the new petcock’s nozzle and secure it with the clamp. Ensure the connection is tight and the line isn’t kinked.
Step 9: The All-Important Leak Check
This is the most critical step. Pour a small amount of fuel (about a quart) into the new tank. Turn the petcock to “ON” or “RES”. Now, meticulously inspect the petcock and the fuel line connection for any signs of leaking. If you see any drips, turn the petcock off, drain the fuel, and fix the connection before proceeding.
Step 10: Reassemble and Test Ride
Once you’re 100% confident there are no leaks, you can reinstall the plastics and the seat. Reconnect your battery. Start the ATV and let it run for a few minutes, again checking for any leaks. Finally, take it for a short, gentle test ride before hitting the trails hard.
Common Problems and Pro Tips for a Flawless Installation
Even a straightforward job can have its hiccups. Here are some common problems with polaris predator 500 gas tank replacement and pro-level tips to help you navigate them like an expert.
Pro Tip: Replace Your Fuel Filter
While the tank is off, you have perfect access to the inline fuel filter. This is the perfect time to replace it. A new filter costs just a few dollars and ensures only clean fuel reaches your engine, maximizing the benefit of your new tank.
Dealing with a Stubborn Petcock
Sometimes the old petcock can be seized in the old tank. A little penetrating oil can help, but if it’s truly stuck, it’s often better to just leave it and use a new petcock on the new tank. It’s not worth cracking the old tank and causing a huge mess.
Ensuring a Leak-Free Seal
The number one mistake DIYers make is overtightening the petcock. This can crack the new tank before you even install it. The key is to use a quality thread sealant and tighten it until it’s just snug. The sealant does the work, not brute force. These are some of the most important polaris predator 500 gas tank replacement best practices to remember.
Post-Installation Care and Maintenance
You’ve done the hard work; now let’s make it last. A little preventative care will keep your new tank in top shape for years to come. This simple polaris predator 500 gas tank replacement care guide will protect your investment.
Protect from UV Damage
The sun is the biggest enemy of plastic gas tanks. When not in use, store your ATV under a cover or indoors. Applying a plastic-safe UV protectant spray a few times a year can also significantly slow down the fading and embrittlement process.
Use Fuel Stabilizer
If you plan on storing your Predator for more than a month, add a quality fuel stabilizer to the tank. This prevents the gasoline from breaking down, gumming up your carburetor, and potentially damaging the inside of your new tank.
Sustainable and Eco-Friendly Gas Tank Replacement Practices
Being a responsible off-roader means taking care of our environment. A sustainable polaris predator 500 gas tank replacement is easier than you think.
First, never dump old gasoline. Take it to your local hazardous waste disposal facility or many auto parts stores will accept it for recycling. For the old tank, check with your local recycling center. While not all centers accept fuel-contaminated plastics, some have programs for it. This is the core of an eco-friendly polaris predator 500 gas tank replacement.
Frequently Asked Questions About Polaris Predator 500 Gas Tank Replacement
How do I know if my Predator 500 gas tank needs replacing?
The most obvious signs are visible cracks, fuel weeping from seams or mounting points, or a strong smell of gasoline around the ATV when it’s not running. Severe discoloration and a chalky, brittle texture are also clear indicators that the plastic has degraded and is due for replacement.
Can I repair a cracked plastic gas tank instead of replacing it?
While plastic welding kits exist, we at FatBoysOffroad strongly advise against it for a gas tank. The vibration and pressure changes on an ATV mean a repair is very likely to fail, putting you right back in a dangerous situation. Replacement is the only safe and reliable solution.
Do aftermarket tanks hold more fuel than the stock one?
Some aftermarket manufacturers offer oversized or “desert” tanks that can increase your fuel capacity, extending your range on long rides. Just be sure to check that they are compatible with your Predator 500’s stock plastics and seat configuration before purchasing.
Swapping out your gas tank is one of the most rewarding DIY jobs you can do. It directly impacts your safety, your quad’s performance, and its overall look. By following this guide and taking your time, you’ve not only saved money but also gained valuable experience working on your machine.
Now, fill that new tank up, double-check your work, and get back out there. The trails are calling!
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