Replacing the fuel pump on a Polaris Sportsman 500 can be a challenging task. While there are some step-by-step guides and community forums offering advice and potential solutions, it is important to approach this repair with caution and a good understanding of the vehicle's mechanics. The fuel pump's location, for instance, varies depending on the model year and type of Sportsman 500, with some pumps located on the upper frame near the left front wheel well, and others inside the fuel tank. Additionally, finding a suitable replacement pump at a reasonable price can be difficult, with some pumps only available as part of a larger assembly. Nevertheless, with perseverance, creativity, and mechanical know-how, it is possible to successfully replace the fuel pump on a Polaris Sportsman 500.
Characteristics | Values |
---|---|
Fuel pump location | Upper frame, left front wheel well, aft of top of strut; or inside the tank |
Fuel pump replacement | Whole unit (tank and all) is expensive; suitable replacement pumps may be available from Quantum or by using automotive fuel pumps from a store like Napa |
Fuel pump priming | Cycle the key on and off 6 times; wait 3 seconds on the on position and 5 seconds on the off position; turn the key to start and wait 5 seconds or until it starts |
Fuel pump troubleshooting | Ensure the regulator is working and that the plastic body of the module is not broken |
What You'll Learn
Disconnecting the fuel line
First, locate the fuel pump wires and disconnect them by unplugging the connector. This will involve squeezing the tabs on the white connector together, pushing the locking tab through to the other side, and then pulling the fuel line off. It is important to place a towel under the connector beforehand to catch any dripping fuel. Ensure you have protective gear on, such as gloves and eye protection, to shield yourself from any fuel spills.
Next, you will need to relieve the fuel pressure from the line. To do this, start the ATV and let it run until the pressure is released. Be cautious and avoid any open flames or sparks during this step, as the fuel is highly flammable. Once the pressure is released, you can now focus on the fuel line itself.
Locate the fuel line where it connects to the fuel pump. You will need to carefully disconnect this line from the pump, ensuring that you do not damage the line or any surrounding components. Gently pull and wiggle the line to detach it from the pump. If necessary, use a line disconnect tool to carefully pry the line off without causing any damage. Be prepared to catch any residual fuel that may spill from the line with a suitable container.
Once the fuel line is disconnected, you will need to clean the connector thoroughly before reinstalling it. Ensure that you follow the proper safety procedures when handling fuel and fuel lines, including working in a well-ventilated area and disposing of any fuel-soaked materials properly.
By following these steps, you can successfully disconnect the fuel line on your Polaris Sportsman 500. Remember to work carefully and refer to a repair manual or seek professional assistance if you encounter any difficulties. Safety should always be your top priority when working with fuel systems.
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Removing the fuel tank
To remove the fuel tank on a Polaris Sportsman 500, you will first need to access the tank by removing the front storage box and plastics. This will involve unscrewing and detaching various components to expose the tank. Ensure you have a good understanding of the fuel tank's location and the steps required before beginning the removal process.
Once you have located the fuel tank, you will need to disconnect the fuel lines and any other relevant components attached to it. Place a towel under the connector to catch any dripping fuel when disconnecting the lines. To disconnect the fuel line, squeeze the tabs of the white connector together, then push the locking tab through to the other side, and finally, pull the fuel line off.
After detaching the fuel lines, you will need to unbolt the fuel tank to release it from its mounting. This process may vary depending on the make and model of your Polaris Sportsman 500, so refer to your specific model's manual or seek advice from a mechanic if you are unsure.
When removing the fuel tank, exercise caution and ensure you are working in a well-ventilated area to avoid inhaling fumes. It is also important to wear appropriate safety gear, such as gloves and eye protection, to safeguard against any fuel spills or debris.
After successfully removing the fuel tank, you can proceed to replace the fuel pump or perform any other necessary maintenance tasks. Remember to re-install the fuel tank securely and connect all the relevant lines and components before operating your Polaris Sportsman 500 again.
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Locating the fuel pump
If you have a carbureted model of the 2006 Polaris Sportsman 500, the fuel pump can be found on the upper frame, left front wheel well, aft of the top of the strut.
For older models of the Polaris Sportsman 500, such as the 2000 model, the fuel pump is located on the left-hand side of the frame in the wheel well area.
It is important to identify the specific model of your ATV to determine the exact location of the fuel pump. The model information can be found on the VIN number, which will help in identifying the fuel pump location and the appropriate replacement parts.
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Choosing a replacement pump
When choosing a replacement fuel pump for your Polaris Sportsman 500, there are a few things to consider. Firstly, it is important to identify the correct fuel pump for your specific model and year. The Polaris Sportsman 500 has different fuel pump designs depending on the year of manufacture and whether it is a carbureted or EFI (electronic fuel injection) model. For example, for a 2006 Polaris Sportsman 500 EFI, the fuel pump is located inside the fuel tank, while for a 2005 model, it is on the left side of the frame in the wheel well area.
Once you have identified the correct fuel pump type, you can start looking for a replacement. One option is to purchase a new, original equipment manufacturer (OEM) replacement fuel pump assembly. This option can be quite expensive, as some users have mentioned prices of around $1000 for the assembly. You may be able to find a used OEM assembly for a lower price, but ensure that it is in good working condition.
Another option is to look for a suitable aftermarket replacement fuel pump. Aftermarket parts can offer a more affordable alternative, but it is important to ensure that the part is compatible with your specific Polaris Sportsman 500 model. Some aftermarket fuel pumps may require minor modifications or custom plumbing to fit your ATV. It is recommended to consult a mechanic or a Polaris dealer to ensure the correct part is selected and properly installed.
Additionally, you may also consider using a universal fuel pump designed for automotive applications. For example, a fuel pump from a Ford Fiesta or Focus may be adapted to fit the Polaris Sportsman 500, but it will require careful selection of compatible fuel hoses and plumbing. This option requires more creativity and craftsmanship but can be a cost-effective solution.
When choosing a replacement fuel pump, it is important to consider the quality and durability of the part. Fuel pumps are critical components, and a failure can leave you stranded. Opting for a higher-quality fuel pump from a reputable manufacturer can provide better performance and a longer service life. Additionally, paying attention to the quality of the fuel hoses is crucial, especially if they will be submerged in the fuel tank. Regular fuel hoses may degrade over time when exposed to gasoline, so it is recommended to use specialised fuel injection hoses from reputable brands like Gates or Goodyear.
Finally, before purchasing a replacement fuel pump, it is advisable to troubleshoot and identify the root cause of the issue. In some cases, a problem with the fuel pump may be caused by a faulty regulator or another component in the fuel system. Checking the regulator and fuel pressure can help determine if the fuel pump requires replacement or if there is another underlying issue.
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Reinstalling the fuel pump
To reinstall the fuel pump on your Polaris Sportsman 500, follow these steps:
Firstly, ensure that the connector is clean. Then, you can begin the reinstallation process, which involves reversing the steps taken to remove the fuel pump.
To disconnect the fuel line, 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.
To prime the system, cycle the key on and off 6 times, waiting 3 seconds in the 'on' position and 5 seconds in the 'off' position. Finally, turn the key to start and wait 5 seconds or until the engine starts. If it doesn't start, simply repeat the process.
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Frequently asked questions
The fuel pump is located inside the tank for EFI models. For carbureted models, it is located on the left-hand side of the frame in the left front wheel well area.
Disconnect the fuel pump wires via the plug. Start the ATV to get the fuel pressure out of the line. Place a towel under the connector to catch the dripping fuel. Squeeze the tabs of the white connector together, then push the locking tab through to the other side, and pull the fuel line off.
Ensure that the connector is clean, then reinstall in reverse.
Brown is ground, violet/white is the gas gauge ohm wire, and red/dark green is the power wire to the pump.
You can try Powersportsnation.com for a used fuel pump. You can also try using an automotive fuel pump from a car, such as a Ford Fiesta or Focus.