Replacing The Fuel Pump In Your Rzr 800: Step-By-Step Guide

If you're experiencing issues with your Polaris RZR 800 fuel pump, you may need to replace it. While there are various aftermarket options available, it is recommended to use an OEM fuel pump to ensure compatibility and optimal performance. The process of replacing the fuel pump involves disassembling the fuel tank and carefully removing the old pump, making sure not to damage the plastic ring where the pump mounts. It is also important to verify the part number and compatibility of the new fuel pump before installation. Additionally, it is suggested to inspect and replace any other components that may be causing fuel system issues, such as the strainer and fuel pressure regulator.

Symptoms of a failing fuel pump

A failing fuel pump in a Polaris RZR 800 can present itself in several ways. The earliest sign is the need for increased throttle pedal input, but the engine still runs OK. Then you may experience sputtering, backfiring, and weak performance under a load but idle is fine. Finally, the machine just won't start or run.

Other symptoms of a failing fuel pump include a loss of power, an inability to go over 40 mph, and maxing out at 5200 rpms. However, these issues could also be caused by other factors such as a dirty air filter, clogged fuel injectors, or a faulty spark arrestor.

It is recommended to listen carefully when turning the key to "ON". If you hear a whining noise from the fuel pump as it brings the fuel rail up to pressure, this could indicate a problem. You can also test the fuel pump pressure using a fuel pump test kit to determine if it is functioning correctly.

Aftermarket fuel pumps

When it comes to aftermarket fuel pumps for the Polaris RZR 800, there are a variety of options available. However, it is important to note that some mechanics have reported issues with aftermarket fuel pumps, and prefer to use OEM fuel pumps instead.

For the Polaris RZR 800 models from 2008 to 2010, the fuel pump with part number 2521011 is compatible. This pump is available from sellers on eBay and Amazon. For the 2011 to 2014 models, the fuel pump with part number 47-1011 is compatible, and this can also be found on eBay and Amazon.

There are also a number of other fuel pump assemblies compatible with the Polaris RZR 800, available on Amazon and eBay. These assemblies include part numbers 47-1019, 2521201, and 2204403. Additionally, some people have reported using a fuel pump from AutoZone, specifically the Airtex E8335, for the 2008 model.

It is important to ensure that you are purchasing the correct fuel pump for your specific RZR 800 model, as the pumps vary between model years.

Removing the fuel pump

The first step in replacing the fuel pump on your Polaris RZR 800 is to remove the old one. Here is a step-by-step guide on how to do this:

Step 1: Park your RZR on a flat, level surface and engage the parking brake. Disconnect the negative battery terminal to prevent any accidental electrical discharge during the process.

Step 2: Locate the fuel pump. It is inside the fuel tank, so you will need to remove the fuel tank from the vehicle. This process can vary depending on your specific model, but it usually involves draining the fuel, removing the fuel lines and hoses, and then unbolting and lifting out the fuel tank.

Step 3: Once you have accessed the fuel pump, carefully disconnect any electrical connectors and fuel lines attached to it. Make sure you have a container ready to catch any fuel that may spill during this process.

Step 4: Now, you need to remove the fuel pump from the fuel tank. This step can be tricky, as the OEM screws tend to spin the nuts embedded in the tank plastic. Be very careful when attempting to remove these screws, as you do not want to deform the plastic ring where the fuel pump mounts. If the screws won't come out, you may need to pry them out gently with a flat-head screwdriver, being mindful not to damage the surrounding plastic.

Step 5: With the screws removed, you should now be able to lift the fuel pump out of the fuel tank. Take note of how the fuel pump is positioned and oriented within the tank, as you will need to install the new one in the same way.

Step 6: Before disposing of the old fuel pump, it is a good idea to inspect it for any signs of damage or wear. This can help you identify and prevent any potential issues with your new fuel pump down the line.

Step 7: Clean the area around the fuel pump mounting point inside the fuel tank. Ensure that there is no dirt or debris that could potentially contaminate your new fuel pump or interfere with the sealing process.

Step 8: With the old fuel pump removed, you are now ready to install the new one. Make sure you have a compatible replacement fuel pump ready, as well as any necessary gaskets or seals.

Note: Always refer to your owner's manual or a trusted mechanic if you are unsure about any steps or procedures. Working with fuel and electrical systems can be dangerous if not done properly.

Installing the new fuel pump

To install the new fuel pump, begin by carefully prying out the old pump and embedded nuts, being mindful not to deform the plastic ring where the fuel pump mounts, as this may make sealing the new pump difficult.

Next, fit the new fuel pump into the mounting ring, ensuring that the pump is securely attached and that the plastic ring is not deformed.

Once the new fuel pump is in place, you may need to replace the embedded nuts with new ones to ensure the pump is securely fastened. Take one of the old screws to a hardware store to find the correct size, and purchase a set of brass wood insert nuts that match.

Finally, connect the fuel pump to the fuel lines and electrical system, following the manufacturer's instructions for your specific fuel pump model. Ensure all connections are secure before starting the engine.

Fuel pump maintenance

Fuel pumps are critical components of a vehicle's fuel system, transferring fuel from the tank to the engine. Regular maintenance and timely repairs are essential to ensure the smooth operation of your vehicle and prevent costly issues down the line. Here are some detailed instructions for maintaining your fuel pump:

Weekly Visual Inspections

Conduct routine visual inspections of your fuel pump at least once a week to identify any signs of wear or damage. Check for leaks on the pump, filters, hoses, nozzles, joints, and fittings. Early detection can prevent potential breakdowns and costly repairs. Keep the pump clean using a degreaser and gentle cleanser to prevent the spread of germs, as fuel pumps are frequently touched. Be careful not to use harsh solutions, as ammonia-based cleansers can damage the screens and other vital components.

Underground Tank Checks

If you have an underground tank, regularly inspect the overfill alarms to ensure they are functioning correctly. These alarms play a crucial role in identifying leaks promptly, helping you address potential hazards and avoid costly repairs.

Preventative Measures

• Use high-quality fuel from reputable sources.
• Regularly replace the fuel filter according to the manufacturer's recommendations.
• Keep the fuel tank at least one-quarter full to prevent pump damage and sediment buildup.
• Address any fuel system issues as soon as they arise to prevent further complications.
• Perform regular engine tune-ups to maintain overall vehicle health.

Safety Considerations

When working on a fuel pump or the fuel system, always prioritize safety:

• Disconnect the battery before beginning any repairs.
• Work in a well-ventilated area to avoid inhaling fuel fumes.
• Wear protective gloves and eyewear to prevent contact with fuel and debris.
• Keep a fire extinguisher nearby to handle any sparks or ignition sources.
• Properly dispose of any old fuel or components according to local regulations.

Repair Techniques

If your fuel pump requires replacement:

• Choose a high-quality replacement pump that meets OEM specifications.
• Properly prime the new pump before installation.
• Ensure secure electrical connections and proper mounting.

By following these maintenance and repair practices, you can maximize the efficiency of your fuel pump, minimize downtime, and ensure the longevity of your vehicle's fuel system.

Frequently asked questions