Replacing Fuel Pump In Polaris Sportsman: Step-By-Step Guide

If you're looking to replace the fuel pump in your 2006 Polaris Sportsman 500, you've come to the right place. This is a fairly common issue, with fuel pumps often needing to be replaced due to damage from fuel gelling or simply general wear and tear. The good news is that you can absolutely find replacement parts without breaking the bank. While Polaris only sells the entire tank and fuel pump assembly as a unit, there are third-party options available that can save you a pretty penny.

Now, before you get started on the replacement, you'll need to locate the fuel pump. In 2006 Polaris Sportsman 500 models, the fuel pump is located inside the tank. So, get ready to get your hands dirty!

Disconnecting the fuel line

Step 1: Prepare the ATV

Before beginning any work on your ATV, it is important to ensure it is switched off and that you are wearing appropriate protective gear, such as gloves and eye protection. Locate the fuel tank and place a towel underneath the connector to catch any dripping fuel. This will help to avoid any spills or messes during the disconnection process.

Step 2: Access the Fuel Pump

To disconnect the fuel line, you will need to access the fuel pump. This may involve removing the front storage box and any plastics or panels that are blocking your access to the fuel tank. Carefully set aside any removed parts in a designated area to ensure you don't misplace anything.

Step 3: Disconnect the Fuel Line

Now, you will need to disconnect the fuel pump wires via the plug. Start the ATV to release the fuel pressure from the line. Once the pressure is released, carefully squeeze the tabs of the white connector together and then push the locking tab through to the other side. At this point, you can gently pull the fuel line off. Be cautious, as the fuel line may still contain some fuel.

Step 4: Clean the Connector

Before reinstalling the fuel line or performing any other maintenance on your ATV, it is important to clean the connector thoroughly. Ensure that it is free of any dirt, debris, or residue that could impact the performance of your vehicle.

Step 5: Reinstallation

When you are ready to reinstall the fuel line, make sure that the connector is clean and free of any debris. Reverse the disconnection process by pushing the fuel line back into place and securing it with the locking tab. Ensure that all wires are properly connected and secured before starting your ATV.

By following these steps, you can safely and effectively disconnect and reinstall the fuel line of your 2006 Polaris Sportsman 500. Remember to take your time, work carefully, and refer to a certified mechanic or ATV specialist if you have any questions or concerns during the process.

Locating the fuel pump

To locate the fuel pump of a 2006 Polaris Sportsman 500, first determine whether your ATV is a carbureted model or an EFI model. The fuel pump on a carbureted model is located on the left-hand side of the frame in the front left wheel well area. If your ATV is an EFI model, the fuel pump will be located inside the fuel tank.

One way to determine whether your ATV is a carbureted model or an EFI model is to look for the label "EFI" on your ATV. If you are unable to find this label, your ATV is likely a carbureted model.

If you are unsure, you can also check the Polaris Parts Fiche to determine whether your model is an EFI model.

Fuel pump replacement options

The fuel pump in a 2006 Polaris Sportsman 500 is located inside the fuel tank. This means that to replace the fuel pump, you will first need to remove the fuel tank from the ATV.

Fuel Pump Options

There are a few options available when it comes to replacing the fuel pump in your 2006 Polaris Sportsman 500. Here are some of the options available:

• OEM Replacement Fuel Pump: This option will be the most expensive, as it requires purchasing the entire fuel tank and fuel pump assembly from Polaris. However, it will be a direct replacement and should bolt straight into the existing mounting points.
• Aftermarket Fuel Pump Kit: There are several aftermarket fuel pump kits available online that are compatible with the 2006 Polaris Sportsman 500. These kits typically include the fuel pump, strainer, regulator, and any other necessary components for installation. Some of the brands offering these kits include HFP, OSIAS, WFLNHB, munirater, AIVWUMOT, and Dasbecan.

Considerations

When replacing the fuel pump, it is important to consider the quality and compatibility of the replacement pump.

• Quality: Ensure that the replacement fuel pump is of good quality and has been tested to output the correct PSI for your vehicle.
• Compatibility: Verify the compatibility of the replacement fuel pump with your specific ATV model and year. Some fuel pumps may only be compatible with certain engine types (e.g. EFI models) or may have different mounting points, requiring modifications for installation.

Additional Components

In addition to the fuel pump itself, there are a few other components that you may need to replace or purchase separately:

• Fuel Filter: It is generally recommended to replace the fuel filter when replacing the fuel pump.
• Fuel Lines: If your existing fuel lines are damaged or deteriorated, you may need to replace them.
• Hose Clamps: Depending on the kit you purchase, you may need to supply your own hose clamps to secure the fuel lines.

Installation

The installation process for the new fuel pump will depend on the specific kit you purchase. However, here are some general steps to give you an idea of the process:

• Remove the front storage box and plastics to access the fuel tank.
• Disconnect the fuel lines and electrical connectors from the fuel pump.
• Remove the fuel tank from the ATV.
• Remove the old fuel pump from the fuel tank and install the new fuel pump, ensuring all connections are secure.
• Reinstall the fuel tank, fuel lines, and electrical connectors.
• Prime the fuel system by cycling the key on and off several times, following the specific procedure for your ATV.

When replacing the fuel pump in your 2006 Polaris Sportsman 500, you have a few options to choose from, including OEM and aftermarket solutions. It is important to consider the quality and compatibility of the replacement pump, as well as any additional components that may need to be replaced. The installation process will vary depending on the specific kit you purchase, but generally involves removing the fuel tank and fuel pump, and then reinstalling the new components.

Installing the new fuel pump

To install the new fuel pump, follow these steps:

Firstly, ensure you have disconnected the fuel line from the old pump. Place a towel under the connector to catch any dripping fuel. Next, squeeze the tabs of the white connector together and push the locking tab through to the other side. Then, pull the fuel line off.

Now, you can begin installing the new fuel pump. Start by cleaning the connector and reinstalling it in reverse. Make sure to prime the system by cycling the key on and off 6 times, waiting 3 seconds in the 'on' position and 5 seconds in the 'off' position. Turn the key to start and wait 5 seconds or until the engine starts. If it doesn't start, simply repeat the process.

To disconnect the fuel pump wires, via the plug, start the ATV to relieve the fuel pressure from the line. Ensure you place a towel under the connector to catch any fuel that may drip out.

Finally, check your new fuel pump for any additional parts that may need installing. For example, some fuel pumps come with a strainer and regulator, or a flex hose that will need to be cut to the correct length.

Priming the system

To prime the fuel system of a Polaris Sportsman 500, you need to cycle the key in the ATV's ignition a few times. This is a process that needs to be done when you change the fuel pump and put everything back together.

Here's a step-by-step guide on how to prime the system:

• Cycle the key on and off 6 times.
• Wait 3 seconds in the "on" position and 5 seconds in the "off" position.
• Turn the key to the start position and wait 5 seconds or until the engine starts.
• If the engine doesn't start, repeat the cycle and retry.

It is also recommended to pressurize the fuel tank to no more than 4 PSI. Open the drain on the carb fuel bowl, and when the fuel is flowing steadily from the bowl drain, close the drain screw. Then, start the engine and let it idle for about 3 minutes.

By following these steps, you should be able to successfully prime the fuel system of your Polaris Sportsman 500 after changing the fuel pump.

Frequently asked questions