Replacing Fuel Pump In Polaris Ranger 700: Step-By-Step Guide

If you're experiencing issues with your Polaris Ranger 700's fuel pump, you may need to replace it. This can be done by first performing a fuel pressure test to determine if the fuel pump is the issue, and then removing the fuel line, power supply, and pump assembly before installing the new pump. It is important to be cautious when performing this process as you will be dealing with gasoline and ensuring you are not around any ignition sources. Additionally, you can refer to your machine's service manual for specific instructions and safety precautions.

Fuel pump replacement options

If you're looking to replace the fuel pump on your Polaris Ranger 700, there are a few options available to you. Here is some detailed information on the process and the replacement parts you can choose from.

When to Replace Your Fuel Pump

If you notice a lack of power in your Polaris Ranger 700, it could be a sign that your fuel pump needs to be replaced. Symptoms such as trouble climbing steep grades, engine stalling, or a feeling that the engine is starving for fuel may indicate a problem with the fuel pump. To confirm, you can perform a fuel pressure test and refer to your machine's service manual for the correct pressure range.

OEM Replacement Fuel Pump

One option for replacement is to purchase an OEM (Original Equipment Manufacturer) fuel pump assembly from Polaris. This option can be expensive, with dealerships quoting around $500 to $600 for a new assembly. However, it is important to note that you may not need to replace the entire assembly, as often only the fuel pump and fuel pressure regulator are defective.

Aftermarket Fuel Pump Options

There are also several aftermarket fuel pump options available that can be more cost-effective than the OEM assembly. These fuel pumps are designed to fit the Polaris Ranger 700 and can be purchased individually, saving you money. Here are some options:

• FPF Fuel Pump with Regulator: This fuel pump and regulator kit is designed for Polaris Ranger models with EFI. It is more reliable than the stock pump and does not require any wiring or modifications for installation. The install time is estimated at 20-30 minutes. This pump flows about 35% more than the stock pump, making it suitable for turbo and modified engines.
• QFS OEM In-Tank Fuel Pump Assembly: This fuel pump assembly is a direct replacement for the Polaris Ranger 700 and other Polaris Ranger models. It is designed to fit the 2006-2013 Polaris Ranger 700 EFI/XP/Crew.
• Dasbecan Electric Fuel Pump Assembly: Compatible with the 2008-2009 Polaris Ranger 700, this assembly provides a direct replacement for the original fuel pump.
• KARSEE 2204306 Fuel Pump Assembly: Compatible with the 2008-2009 Polaris Ranger 700 EFI/XP/Crew, this assembly offers a cost-effective replacement option.

Installation Process

When replacing the fuel pump on your Polaris Ranger 700, it is important to follow the correct procedure to ensure a safe and successful installation. Here are the key steps:

• Clean any dirt or dust from the top of the tank before removing any hoses.
• Remove the fuel line by pressing in on the two tabs to release the quick connect.
• Unplug the power supply. You may need adjustable pliers to remove the twist-off retainer ring.
• Gently lift the pump assembly out of the tank, being careful not to hang the fuel filter or fuel level arm.
• Expose the fuel pump by prying up on the snaps of the pump assembly cap using a small flat-head screwdriver.
• Unplug the two-wire plug from the top of the fuel pump assembly and slide it down.
• Gently pry up on the clips for the plastic housing and slide it down to access the fuel pump.
• Unplug the fuel pump and pull it free from the housing.
• To install the new pump, simply repeat the process in reverse.

Remember to exercise caution when working with gasoline and ensure there are no ignition sources nearby.

Fuel pressure testing

Step 1: Acquire the Necessary Tools

You will need a fuel pressure gauge, which you can purchase at your local auto parts store. Additionally, you may require an adaptor to attach the pressure hose to the fuel rail's Schrader valve.

Step 2: Prepare the Engine

Turn the key to the "run" position without starting the engine. You should hear a buzzing sound for about three to four seconds, indicating that the fuel pump is cycling. If you don't hear this sound, there may be an issue with the power supply to the fuel pump.

Step 3: Check Fuel Pump Pressure

Once you've confirmed the fuel pump is cycling, it's time to test the fuel pump's pressure. Connect the fuel pressure gauge to the Schrader valve and start the engine. Refer to your Polaris Ranger 700 service manual for the correct pressure range, which is typically around 39 PSI +/- 3 PSI.

Step 4: Observe the Pressure Gauge

With the engine running, observe the needle on the pressure gauge. It should rise to a certain pressure and then slightly lower when the engine shuts off. If the needle consistently drops, it may indicate a faulty check valve in the fuel pump.

Step 5: Test Under Acceleration

To further diagnose fuel pump issues, you should also check the fuel pressure under acceleration. Turn the key to the "on" position and observe the pressure gauge while revving the engine. The needle should rise and remain consistent, even with increased throttle.

Step 6: Compare with Specifications

Compare the pressure readings you obtain with the specifications provided in your service manual. If your fuel pressure is outside the specified range, it indicates a fuel pump issue.

Step 7: Take Necessary Action

If your fuel pressure test indicates a problem, you may need to replace the fuel pump or address any other underlying issues. Always refer to your service manual for specific instructions and safety precautions when working on your Polaris Ranger 700.

It is important to note that fuel pump issues can be complex, and there may be other factors contributing to the problem. Therefore, it is always recommended to consult a qualified mechanic or a Polaris service center if you are unsure about the results of your fuel pressure test or the necessary repair procedures.

Removing the pump from the tank

To remove the pump from the tank, you will need to first remove the fuel line by pressing in on the two tabs to release the quick connect. The clip may not come all the way out of the fitting. Then, simply unplug the power supply.

The retainer ring can be tough to twist off and there may not be much room to work with. You may need a large pair of adjustable pliers to get it moving if it is too tough to twist by hand.

Gently and carefully lift the pump assembly out of the tank, being careful not to hang the fuel filter or fuel level arm on the inside of the tank. It will take some wiggling, but it will come out. The wires and piping can be brittle, so be cautious when handling the assembly. Also, take care not to drop the large O-ring seal into the tank when pulling the fuel pump out.

Reinstalling a new pump

Once you have the new fuel pump, you can begin the process of reinstallation. This involves repeating the steps for removing the old pump but in reverse.

Firstly, you will need to secure the fuel filter to the new pump using the small retaining washer. Be careful with this small part, as it needs to be reused. Use a small flathead screwdriver to carefully slip the edge under the retainer and the pump filter, prying upwards with a smooth and gentle motion.

Next, you can attach the plug with two wires to the top of the fuel pump assembly. Slide the plastic housing down and then gently pry up the clips to remove it. Now, you can unplug the pump itself and pull it free of the housing.

The new pump can now be placed into the pump assembly. You can use a small, deep socket to press the retaining washer back on. Ensure that the pump is held securely into the bottom of the assembly by a cap that simply snaps on.

Now, you can replace the twist-off retainer ring, which can be tough to manage without a large pair of adjustable pliers. Then, plug the power supply back in and reconnect the fuel line by pushing the tabs back in.

Finally, carefully lower the pump assembly back into the tank, being mindful not to hang the fuel filter or fuel level arm on the inside of the tank. Ensure that you do not drop the large O-ring seal into the tank.

It is important to note that this process should be taken seriously, as you are dealing with items covered in gasoline. Make sure you are not working near any ignition sources.

Fuel pump wiring

Before you begin working on the fuel pump, it's important to ensure that you have the correct replacement part. The fuel pump assembly for the Polaris Ranger 700 typically includes the fuel pump itself, a fuel pressure regulator, and a fuel filter strainer. When purchasing a replacement fuel pump, make sure it is compatible with your specific Polaris Ranger 700 model year.

Now, let's discuss the wiring:

Basic Wiring Tips:

• Always work in a well-ventilated area and avoid any sources of ignition, such as cigarettes or heaters. Gasoline fumes can be dangerous, so take necessary precautions.
• Before removing any hoses or components, clean any dirt or dust from the top of the fuel tank. This will help prevent debris from falling into the tank.
• When handling the fuel pump assembly, be cautious as the wires and piping can be brittle.
• Pay close attention to the wiring connections. Over time, the wires can become brittle or damaged, leading to potential connection issues.
• If you need to disconnect any wiring harnesses or plugs, do so gently. Use a small flat-head screwdriver if necessary, being careful not to damage the wires or connectors.
• When installing the new fuel pump, follow the reverse process of removal. Ensure that all wiring connections are secure and properly routed.
• If you're sourcing a replacement fuel pump from a local auto parts store, you may only need to replace the pump itself, rather than the entire fuel pump assembly. This can save you money.
• Some aftermarket fuel pumps may not require any wiring modifications or adjustments. However, it's important to consult the instructions provided with the replacement pump to ensure a proper installation.

Remember to consult your Polaris Ranger 700 service manual for specific wiring diagrams and schematics related to the fuel pump. This will help you identify the correct wires and connections during the installation process.

Frequently asked questions