Replacing A Polaris Snowmobile Fuel Pump: A Step-By-Step Guide

If you're looking to replace the fuel pump on your 1997 Polaris snowmobile, you've come to the right place. This guide will take you through the process step-by-step, ensuring you have everything you need to get your snowmobile running smoothly again.

Fuel pump repair kits

If you are looking to repair the fuel pump on your 1997 Polaris snowmobile, there are a variety of fuel pump repair kits available. These kits are designed to help you fix your fuel pump rather than replace it, which can save you money and time. Here is some information about fuel pump repair kits for your 1997 Polaris snowmobile:

First, it is important to identify the type of fuel pump in your snowmobile. The most common types are the Mikuni carb pump and the Polaris fuel pump. Once you have identified the type of fuel pump you have, you can choose the appropriate repair kit.

There are several reputable vendors that offer fuel pump repair kits for Polaris snowmobiles. For example, Vertex offers a range of repair kits for different styles of fuel pumps, including round type, pentagon style, dual and triple pumps, and old-style round type. These kits are designed to repair specific components of the fuel pump, such as the seals and gaskets, and can help extend the life of your fuel pump.

Another option is the Fuel Pump Rebuilt Kit offered by PWC Engine on Amazon. This kit is compatible with the Polaris Mikuni 700 RMK and SKS 1997-2005 700cc snowmobiles. It is a high-performance kit that meets or exceeds OEM standards. The kit includes all the necessary components to rebuild your fuel pump and improve its performance.

Sports Parts Inc. also offers a fuel pump repair kit for Polaris snowmobiles, which includes the necessary parts to repair or replace the seals and gaskets in your fuel pump. This kit is designed to work with a variety of fuel pump models, so it is important to verify compatibility with your specific fuel pump before purchasing.

When considering a fuel pump repair kit, it is important to review the compatibility of the kit with your specific snowmobile model and year. Additionally, it is advisable to consult a professional or a repair manual for guidance on properly repairing or replacing your fuel pump to ensure the safety and optimal performance of your snowmobile.

Fuel pump replacement

Step 1: Purchase a Replacement Fuel Pump

First, you will need to purchase a replacement fuel pump for your 1997 Polaris snowmobile. You can find fuel pumps for sale online, and some retailers may also offer repair kits. When purchasing a replacement fuel pump, ensure that it is compatible with your specific Polaris model.

Step 2: Remove the Old Fuel Pump

Before beginning the removal process, refer to your owner's manual for any model-specific instructions or safety precautions. Next, locate the fuel pump in your snowmobile. Depending on your model, the fuel pump may be located near the engine or attached to the air box. Once located, proceed to carefully disconnect the fuel lines and any electrical connections attached to the pump.

Step 3: Install the New Fuel Pump

Install the new fuel pump by connecting it to the fuel lines and securing it in place. Ensure that all connections are secure and properly sealed to prevent fuel leaks.

Step 4: Test the New Fuel Pump

Once the new fuel pump is installed, test it to ensure it is functioning correctly. Start the snowmobile and listen for any unusual noises. Check for fuel leaks around the pump and the fuel lines. If the new pump is functioning properly, you should be able to start and run the engine without any issues.

Step 5: Post-Installation Care

After installing the new fuel pump, it is important to take care of your snowmobile's fuel system to maintain its performance and longevity. Regularly inspect the fuel lines for any signs of degradation or damage, as fuel can degrade rubber hoses over time. Additionally, consider using fuel stabilizers and treatments to maintain the health of your fuel system.

Fuel pump location

The fuel pump in a 1997 Polaris snowmobile is located down by the engine. However, Polaris later recommended mounting the fuel pump on the air box to prevent fuel starvation. This issue was caused by the pulse line getting loaded with spooge, which blocked the pulse line and starved the engine of fuel.

To replace the fuel pump, you will need to purchase a fuel pump repair kit. These are available from various manufacturers, including Vertex and Sports Parts Inc. The correct kit will depend on the style of your fuel pump. For example, Vertex offers repair kits for round type, pentagon style, dual and triple pump, and rectangular Mikuni fuel pumps. Sports Parts Inc. also offers a fuel pump seal as part of its repair kit.

Fuel pump maintenance

Visual Inspections:

• Inspect your fuel pump at least once a week for any signs of wear, damage, or leaks.
• Check the filters, hoses, nozzles, joints, and fittings for any issues.
• Keep the pump clean to preserve its functionality and prevent the spread of germs. Use a degreaser and gentle cleanser, avoiding harsh or ammonia-based solutions that can damage the pump's components.
• In case of spills, promptly soak up excess fuel with absorbent granules, and use a pressure washer for stubborn stains.

Underground Tank Checks:

• Regularly inspect the overfill alarms in your underground tanks to ensure they are functioning correctly.
• These alarms help identify leaks and mitigate potential hazards, so it is important to address any issues promptly.

Nozzles and Connections:

• Check the nozzles and their connection to the dispenser outlet for any leaks or damage.
• Ensure the breakaway function is working correctly in case of sudden pull or tension on the hose.

Hose Retractor:

• Inspect the hose retractor for wear or damage, including the grommet for grooves in the metal on the inner retractors.
• Verify that the cord is in good condition and is not frayed or damaged.

Dispenser Door Gaskets:

Inspect the dispenser door gaskets for any security breaches or skimming devices.

Calibration Seals:

Ensure that the calibration seals are intact and display the correct information.

CRIND Diagnostics:

Clean the card reader and check the display for any graffiti film to ensure a smooth customer experience.

Exterior Damage:

Check the dispenser, including the inner frame, for any exterior damage.

Shear Valve Mounting:

Ensure the shear valve is securely mounted and the dispenser is firmly attached to the island.

Fill and Vapor Riser Caps:

Inspect all fill and vapor riser caps for any damage or missing parts.

Spill Buckets:

• Check spill buckets for the presence of liquid and remove any that is found.
• Inspect for visual damage and report issues promptly.

Spill Bucket Lids:

Examine the lids for any damage, missing parts, or irregularities.

Lid Bolts and Gaskets:

Check all lids for missing bolts and ensure the gaskets are in good condition to maintain a secure seal.

Underground Storage Tanks (USTs) or Underground Containment (UDC) Systems:

• Look for signs of water intrusion in UST sumps, ensuring sensors are correctly placed at the lowest point.
• Inspect UDCs for water presence, assess boot conditions, and verify the proper placement of sensors.

Fuel Filters:

• Regularly replace fuel filters according to the manufacturer's guidelines, based on pump usage and fuel type.
• Inspect filters for any restrictions or clogs that could reduce flow rates and strain the pumps.

Fuel Pump Replacement:

• When replacing the fuel pump, choose a high-quality pump that meets OEM specifications.
• Prime the new pump before installation and ensure secure electrical connections and proper mounting.

Remember to always prioritize safety when working on your fuel system. Disconnect the battery, work in a well-ventilated area, wear protective gear, and keep a fire extinguisher nearby.

Fuel pump issues

To diagnose fuel pump issues, there are several tests you can perform. Start by checking the fuel lines, as clogged or degraded fuel lines can impede fuel flow. Next, examine the pulse line from the engine to the carburettor, as a cracked or clogged pulse line can affect fuel pump function. You can also check for fuel pump pressure by connecting the pulse line to the fuel pump and placing your finger on the end to feel for a pulse while trying to start the engine. Additionally, you can pressurise the fuel tank and observe the clear fuel filter for solid fuel flow to ensure the fuel pump is functioning correctly.

If you suspect that your fuel pump is not working correctly, it may need to be replaced. In some cases, rebuilding the fuel pump may be an option, but it is essential to ensure that all internal components, such as the membrane-type screens, are in good condition. If you are unsure about the condition of your fuel pump, it is recommended to consult a professional or seek advice from experienced individuals.

It is worth noting that fuel pump issues can sometimes be prevented by taking proper maintenance measures. For example, ensuring that your fuel tank remains vented and using non-ethanol fuel with a fuel treatment additive can help maintain the health of your fuel pump and fuel system.

Frequently asked questions