Polaris 500 Sportsman: Changing The Fuel Filter

The Polaris Sportsman 500 HO is an all-terrain vehicle (ATV) that comes equipped with a digital fuel gauge, which will indicate when the vehicle is running low on fuel. The fuel filter on this model should be replaced after every 100 hours of operation or annually, and this task is best left to a dealer. The fuel filter is located under the seat on the right side of the ATV, by the carb. It can be accessed from the right side at the rear of the vehicle, without removing the front storage box.

Fuel filter location

The fuel filter on a Polaris Sportsman 500 is located on the left side of the engine, next to the oil filter. It can be reached from the right side of the ATV from the rear—it cannot be accessed from the front.

To change the fuel filter, you will need to remove the front storage box. There are four bolts inside the box, two screws on the underside of each fender at the outer edge, and one screw through the box edge on either side of both latches. Once these are removed, the box can be taken out, making it easier to access the fuel filter.

The fuel lines have quick-release clips, which can be tricky to remove if you haven't seen one before. The fuel filter should be replaced annually or after every 100 hours of operation.

Step-by-step replacement guide

Step-by-Step Guide to Replacing the Fuel Filter on a Polaris 500 Sportsman

Step 1: Locating the Fuel Filter

Before you begin the replacement, you need to locate the fuel filter. On a Polaris 500 Sportsman, the fuel filter is located on the left side of the engine, next to the oil filter.

Step 2: Gathering Tools and Materials

You will need a replacement fuel filter, which can be purchased from automotive or powersports parts stores, as well as online. It is recommended to refer to your owner's manual or a Polaris dealership for specific parts information. Additionally, you may require basic tools like screwdrivers and wrenches for accessing the fuel filter.

Step 3: Accessing the Fuel Filter

To access the fuel filter, you can approach it from the right side of the ATV at the rear. Removing the front storage box is not necessary but may provide better visibility and ease of access.

Step 4: Detaching the Fuel Lines

The fuel filter is connected to the fuel lines, which need to be carefully detached. Pay attention to the quick-release clips on the fuel lines, as they can be tricky to remove, especially in tight spaces.

Step 5: Removing the Old Fuel Filter

Once the fuel lines are detached, you can remove the old fuel filter. Be cautious of any remaining fuel in the lines, and have a rag or towel ready to catch any spills.

Step 6: Installing the New Fuel Filter

Take the new fuel filter and ensure it is oriented correctly. There should be an arrow on the filter indicating the direction of fuel flow. Connect the fuel lines to the new filter, securely fastening the quick-release clips.

Step 7: Reassembling and Testing

After installing the new fuel filter, carefully reassemble any components that were removed to access the fuel filter. Once everything is back in place, start the engine and check for any leaks around the fuel filter and lines. If there are no leaks, your new fuel filter has been successfully installed!

Notes and Tips:

• It is recommended to replace the fuel filter annually or after every 100 hours of operation.
• Do not attempt to clean the fuel filter; always replace it with a new one.
• Fuel filter replacement can be done in conjunction with an oil and filter change for efficient maintenance.
• Always exercise caution when working with fuel systems, and refer to the owner's manual or a qualified mechanic if you have any questions or concerns.

Fuel filter maintenance

The fuel filter in your Polaris Sportsman 500 should be replaced after every 100 hours of operation or annually. This is a task best performed by your dealer, as it can be tricky to access the fuel filter and remove the quick clips on the fuel lines.

Location of the Fuel Filter

The fuel filter is located on the right side of the ATV by the carb, under the seat. It can be reached from the right side from the rear but not from the front. To access it, you will need to remove the front storage box.

Step-by-Step Guide to Replacing the Fuel Filter

• Remove the front storage box by opening the lid and pulling the screws that hold the latch ring in place. Then, remove the two screws accessible from under the fender on each side.
• Locate the fuel filter and remove the old one.
• Install the new fuel filter, ensuring that you follow the direction arrow on the filter.
• Reattach the quick clips on the fuel lines.
• Put the front storage box back in place, screwing it tightly to secure the fuel filter.

Additional Tips

• It is recommended to use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.
• Do not use fuel with an ethanol content greater than 10 percent.
• Do not attempt to clean the fuel filter.
• Always refuel outdoors or in a well-ventilated area with the engine stopped.

By following these maintenance tips and steps for replacing the fuel filter, you can help ensure the optimal performance of your Polaris Sportsman 500.

Fuel type recommendations

The Polaris Sportsman 500 HO Owner's Manual recommends using either leaded or unleaded gasoline with a minimum pump octane number of 87. It is important not to use fuel with an ethanol content greater than 10%. Octane in excess of 87 will not damage the engine but will typically not result in performance gains.

The RZR Turbo and Pro XP models are exceptions to this rule. They require unleaded fuel with an octane number of 91. Do not use fuel with a rating lower than 91 and do not exceed an ethanol content of 10%. As with the other models, octane in excess of 91 will not damage the engine but will not result in performance gains.

It is also important to note that fuel is mixed differently depending on the season. Summer fuel has a low Reid Vapor Pressure (RVP), preventing vapor lock issues in warm weather. Winter fuel, on the other hand, has a higher RVP, aiding engine starting in cold weather. Therefore, in winter, it is recommended to drain your tank and refill it with fresh winter-blend fuel from a high-volume gas station. After filling the tank, run the engine for 10 to 15 minutes to ensure the fuel system is filled with the fresh winter-blended fuel.

When refueling, always exercise extreme caution and follow safety precautions. Gasoline is highly flammable and explosive, so always refuel outdoors or in a well-ventilated area, free from any sources of flame or sparks. It is also crucial to never carry fuel or other flammable liquids in your vehicle, as this could lead to serious burns or even death.

Fuel stabilisation and treatment

Fuel Stabiliser

It is recommended to use a fuel stabiliser to maintain the quality of the fuel in your Polaris Sportsman 500, especially if you do not use your vehicle frequently or plan to store it. A fuel stabiliser, such as the one offered by Lucas Oil®, will help keep the fuel fresh for up to 24 months during storage and eliminate the need to drain the fuel before storing your vehicle.

Fuel Type

Always use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with an ethanol content greater than 10 percent. Using the wrong type of fuel can cause damage to your engine, so it is important to refuel with the correct type of gasoline.

Refuelling

When refuelling your Polaris Sportsman 500, always do so with the engine stopped and in a well-ventilated area, either outdoors or in a space with good ventilation. Remove the fuel tank cap to add fuel, and remember to always follow safety precautions when handling fuel.

Fuel Filter Replacement

The in-line fuel filter on your Polaris Sportsman 500 should be replaced by an authorised dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter yourself. Regular fuel filter replacement ensures that your fuel system remains free of contaminants, helping to maintain the performance and longevity of your engine.

Fuel System Maintenance

In addition to fuel stabilisation and treatment, proper maintenance of your fuel system is essential. This includes regular inspection and replacement of fuel lines, gaskets, seals, and other components as needed. Keep an eye out for any signs of wear or damage, and always refer to the owner's manual for specific maintenance intervals and procedures.

By following these guidelines on fuel stabilisation and treatment, you can help ensure the reliable performance of your Polaris Sportsman 500 and maximise the lifespan of your fuel system and engine.

Frequently asked questions