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2004 Arctic Cat 400
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Discussion Starter · #1 ·
So after replacing my 5th fuel gauge in my 400 arctic cat I've gotten fed-up and tired of paying the rising prices of the gauges ($45 10 years ago, $105 now)


I spent some time doing research and found this fuel cap & Gauge assembly for $45 Cad on Amazon, and have essentially determined Kelch gauges will work, but the float stick while being the same length is a touch short for 04 400 fuel tanks because once threaded in it rests higher (fuel neck) I believe the optimal length would be 8".

I haven't threaded it into a full tank of fuel yet but I believe this will read empty approximately the same time you switch to reserve (based on old math)

Has anyone found a successful way to plug the old fuel gauge port? I purchased some neoprene and nitrile rubber expansion plugs but can't seem to swell them enough by hand, I'm going to test fit one using my impact/drill just to see if I can swell it enough to seal.

I was wondering about some kind of aluminum plug with O-rings or something that would just be installed and forgotten about.
 

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@Farrix, the sled caps with guage screws onto our era of atv’s. It’s just a matter of finding correct length. I know for a fact as the ATV cap fits my 2016 Bearcat. Bearcat cap w/guage doesn’t fit as it’s way too long. Older ZR chassis’s will have shorter guages. I don’t have one to test this.
As far as the ATV guage, I would fill the glass area with an epoxy to seal it.
 

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Like you, I’m tired of the guages not lasting. However both these guages were changed at the same time. The 300 is perfect and the 400 is bad already. I do use the 400 more but both are always garaged.

 

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Discussion Starter · #4 ·
@660catman The gauge I linked above is a 7" depth Gauge, I've threaded it into my tank and it doesn't hit/rub the bottom, the depth of of the fuel cap itself is a bit shallower (doesn't go as far down the neck) but that's not a big deal as the seal is made by the rubber not the thread.

The fact that it doesn't touch bottom for me is almost a better thing in my mind, I would rather know if I've been travelling one direction and I see my gauge is getting low, that I've got enough fuel to turn and burn back and hopefully still make it.

I'm testing a 1.25" hillman expansion plug to plug the old gauge hole, it may not be a permanent option but if it buys me some time to find a better solution so be it. I might just gut the existing fuel gauge and jam some fuel tank repair putty down the needle hole or something.
 

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Discussion Starter · #6 ·
could u not take the old lens of gas gage and dab about 1/8 of an inch of
urathane car winshield glue. that stuff is gasolene proof when cured.
I would use the old lens, if I had the old lens. pulling the needle out and urethane coating the surface isn't a bad idea though.
 

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I ran across this post while trying to find a solution to the gas guage design flaw. I'm using my 300 for work in a fire hazard zone and it's leaking gas! Does anyone know of a replacement tank, without the bad guage, that would fit these machines? I know it's only been a couple weeks, but how's the expansion seal holding up?
 

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Discussion Starter · #8 ·
Expansion seal worked great where I was riding on the weekend, it took double washer on the nut and using a drill to get it right enough holding it up a bit to get max grip on the seal, 7" gas gauge cap isn't quite long enough next time I'd try an 8"
 
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